Ricoh MP 7503SP Field Service Manual
  1. Manuals
  2. Brands
  3. Ricoh Manuals
  4. All in One Printer
  5. MP 7503SP
  6. Field service manual

Ricoh MP 7503SP Field Service Manual

Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
671
672
673
674
675
676
677
678
679
680
681
682
683
684
685
686
687
688
689
690
691
692
693
694
695
696
697
698
699
700
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
717
718
719
720
721
722
723
724
725
726
727
728
729
730
731
732
733
734
735
736
737
738
739
740
741
742
743
744
745
746
747
748
749
750
751
752
753
754
755
756
757
758
759
760
761
762
763
764
765
766
767
768
769
770
771
772
773
774
775
776
777
778
779
780
781
782
783
784
785
786
787
788
789
790
791
792
793
794
795
796
797
798
799
800
801
802
803
804
805
806
807
808
809
810
811
812
813
814
815
816
817
818
819
820
821
822
823
824
825
826
827
828
829
830
831
832
833
834
835
836
837
838
839
840
841
842
843
844
845
846
847
848
849
850
851
852
853
854
855
856
857
858
859
860
861
862
863
864
865
866
867
868
869
870
871
872
873
874
875
876
877
878
879
880
881
882
883
884
885
886
887
888
889
890
891
892
893
894
895
896
897
898
899
900
901
902
903
904
905
906
907
908
909
910
911
912
913
914
915
916
917
918
919
920
921
922
923
924
925
926
927
928
929
930
931
932
933
934
935
936
937
938
939
940
941
942
943
944
945
946
947
948
949
950
951
952
953
954
955
956
957
958
959
960
961
962
963
964
965
966
967
968
969
970
971
972
973
974
975
976
977
978
979
980
981
982
983
984
985
986
987
988
989
990
Table of Contents

Advertisement

Quick Links

Download this manual
MP 6503SP/MP 7503SP/MP 9003SP
Machine Code: D223/D224/D225
Field Service Manual
May, 2016

Advertisement

Table of Contents
loading

Related Manuals for Ricoh MP 7503SP

Summary of Contents for Ricoh MP 7503SP

  • Page 1 MP 6503SP/MP 7503SP/MP 9003SP Machine Code: D223/D224/D225 Field Service Manual May, 2016...

  • Page 3: General Safety Instructions

    Important Safety Notices Warnings, Cautions, Notes In this manual, the following important symbols and notations are used. • Indicates a potentially hazardous situation. Failure to obey a Warning could result in death or serious injury. • Indicates a potentially hazardous situation. Failure to obey a Caution could result in minor or moderate injury or damage to the machine or other property.

  • Page 4: Reference Material For Maintenance

    Reference Material for Maintenance • Maintenance shall be done using the special tools and procedures prescribed for maintenance of the machine described in the reference materials (service manuals, technical bulletins, operating instructions, and safety guidelines for customer engineers). • In regard to other safety issues not described in this document, all customer engineers shall strictly obey procedures and recommendations described in the "CE Safety Guide".

  • Page 5: Power

    Power • Always disconnect the power plug before doing any maintenance procedure. After switching off the machine, power is still supplied to the main machine and other devices. • To prevent electrical shock, switch the machine off, wait for a few seconds, then unplug the machine from the power source.

  • Page 6: During Maintenance

    During Maintenance General • Before you begin a maintenance procedure: 1) Switch the machine off, 2) Disconnect the power plug from the power source, 3) Allow the machine to cool for at least 10 minutes. • Avoid touching the components inside the machine that are labeled as hot surfaces. Safety Devices •...

  • Page 7: Lithium Batteries

    Lithium Batteries • Always replace a lithium battery on a PCB with the same type of battery prescribed for use on that board. Replacing a lithium battery with any type other than the one prescribed for use on the board could lead to an explosion or damage to the PCB.

  • Page 8: After Installation, Servicing

    • Make sure that the power cord is grounded (earthed) at the power source with the ground wire on the plug. • Connect the power cord directly into the power source. Never use an extension cord. • When you disconnect the power plug from the power source, always pull on the plug, not the cable.

  • Page 9: Special Safety Instructions For Toner

    down. This gives the hard disk time to stop rotating and shut down normally before the machine loses power. • Demonstrate how to disconnect the power plug quickly (by pulling the plug, not the cord) if any of the following events occur: 1) something has spilled into the product, 2) service or repair of the product is necessary, 3) the product cover has been damaged.

  • Page 10: Toner Disposal

    Toner Disposal • Never attempt to incinerate toner, used toner, or empty toner containers (bottles or cartridges). Burning toner can explode and scatter, causing serious burns. • Always wrap used toner and empty toner bottles and cartridges in plastic bags to avoid spillage. Follow the local laws and regulations regarding the disposal of such items.

  • Page 11: Observance Of Electrical Safety Standards

    3. To avoid possible accumulation of ozone in the work area, locate the machine in a large well ventilated room that has an air turnover rate of more than 50 m /hr/person. Observance of Electrical Safety Standards 1. The machine and its peripherals must be installed and maintained by a customer service representative who has completed the training course on those models.

  • Page 12: Laser Safety

    Laser Safety 1. Laser safety labels are attached to the top of the laser unit. Note: The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. 2. The optical housing unit can only be repaired in a factory or at a location with the requisite equipment.

  • Page 13: Symbols And Trademarks

    Symbols and Trademarks Symbols Used in Text Symbol What it means Bushing C-ring Clip Connector E-ring FFC (Flat Film Connector) FFC (Flat Film Connector) FFC (Flat Film Connector) Gear Harness clamp Harness clamp: metal: fusing unit Hook (sensors) Screw: binding screw (round flathead) Screw: binding screw (shoulder, hex head) Screw: black screw (TCRU, fusing unit) Screw: blue...

  • Page 14: Trademarks

    Symbol What it means Spring Standoff Stud screw Timing belt Washer The notations "SEF" and "LEF" describe the direction of paper feed. The arrows indicate the direction of paper feed. In this manual "Main Scan" means "Horizontal" and "Sub Scan" means "Vertical", both relative to the direction of paper feed.
  • Page 15 • Fiery is a registered trademark of Electronics for Imaging (EFI), Inc. • Adobe, Acrobat, Flash, PageMaker, PostScript, PostScript 3, and Reader are either registered trademarks or trademarks of Adobe Systems Incorporated in the United States and/or other countries. • Firefox and Thunderbird are registered trademarks of the Mozilla Foundation. •...
  • Page 16 ® ® Microsoft Windows XP Professional ® ® Microsoft Windows XP Home Edition ® ® Microsoft Windows XP Professional x64 Edition • The product names of Windows Vista are as follows: ® ® Microsoft Windows Vista Ultimate ® ® Microsoft Windows Vista Business ®...
  • Page 17 ® ® Microsoft Windows Server 2008 R2 Enterprise • The product names of Windows Server 2012 are as follows: ® ® Microsoft Windows Server 2012 Foundation ® ® Microsoft Windows Server 2012 Essentials ® ® Microsoft Windows Server 2012 Standard •...

  • Page 18: Table Of Contents

    TABLE OF CONTENTS Important Safety Notices........................... 1 Warnings, Cautions, Notes...........................1 General Safety Instructions..........................1 Responsibilities of the Customer Engineer....................1 Customer Engineer..........................1 Reference Material for Maintenance....................2 Before Installation, Maintenance........................2 Warning Label............................2 Shipping and Moving the Machine..................... 2 Power..............................3 Installation, Disassembly, and Adjustments..................3 Special Tools............................3 During Maintenance............................
  • Page 19 Symbols Used in Text...........................11 Trademarks..............................12 1. Product Information Machine Configuration............................49 Component Layout............................49 Paper Path (With Cover Interposer Tray)....................51 Paper Path (With 9-Bin Mailbox)....................... 52 Drive Layout..............................53 Machine Codes and Peripherals........................55 Peripheral Units............................55 Other Options.............................. 56 Mainframe Options: External......................56 Mainframe Options: Internal......................57 Controller Options: I/F Slots......................
  • Page 20 Operating Environment..........................81 Machine Level.............................. 82 Minimum Space Requirements........................82 Dimensions..............................83 Power Requirements............................ 83 Main Machine..............................85 Accessory Check............................85 Installation Flow............................86 Installation Procedure..........................87 Remove Tapes and Shipping Materials.................... 87 Attach Power Cord to Machine......................98 Remove Development Unit......................... 99 Load Developer..........................
  • Page 21 Important SP Codes: Installation......................142 Drum Heater (Option)........................... 144 Accessories..............................144 Installation..............................144 Install Drum Heater...........................144 Connect the Drum Heater........................ 149 Scanner Heater (Option)..........................151 Accessories..............................151 Installation..............................151 Install Scanner Heater........................151 Connect the Scanner Heater......................155 A3/11"x17" Tray Type 9001 (D482)....................... 157 Accessory Check............................
  • Page 22 Docking............................. 205 Power Cord............................207 Finishing the Installation........................208 Proof Tray Auxiliary Plate.........................208 Finisher SR4080 (D610)..........................210 Accessory Check............................210 Installation..............................211 Auxiliary Trays............................221 Punch Units (B531/A812) .......................... 223 Accessory Check............................223 Installation..............................224 Output Jogger Unit Type 9002B (B513) ....................230 Accessory Check............................
  • Page 23 Auxiliary Trays..........................262 Using Auxiliary Trays........................263 Punch Units (D706)............................267 Accessory Check............................267 Installation Procedure..........................268 Output Jogger Unit Type M25 (D3CJ)......................291 Accessories..............................291 Installation..............................292 Cover Interposer Tray CI4040 (DC3N)......................304 Accessories..............................304 Installation..............................305 Finisher Already Installed?.......................305 Prepare the Finisher.......................... 307 Shipping Tapes and Retainers......................
  • Page 24 Card Reader Bracket Type 3352 (D593)....................351 Accessories..............................351 Installation..............................352 Optional Counter Interface Type M12 (B870)..................358 Accessories..............................358 Installation..............................359 Copy Connector Type M25(D3D3)......................361 Accessories..............................361 Installation..............................361 External Keyboard Bracket Type M3 (D3DH)....................363 Accessories..............................363 Installation..............................363 External Keyboard Only........................
  • Page 25 Ethernet Port LEDs..........................397 Notes for Energy Save Mode Setting..................... 398 IP Address Setting............................398 Extended USB Board Type M19........................401 Accessories..............................401 Installation..............................401 SD Card Options............................403 Overview..............................403 Options Available on SD Cards.......................403 Inserting SD Cards.............................404 Move Exec: Merging Applications ......................405 Undo Exec: Unmerging Applications......................
  • Page 26 Seal Check and Removal.........................424 Installation Procedure..........................425 After Installation Check..........................427 Safety Check..............................427 Check List..............................427 Security Setting.............................. 429 Security Function Installation........................429 Data Overwrite Security........................... 429 Using Auto Erase Memory.......................429 HDD Encryption............................431 Before You Begin the Procedure:....................431 Enable Encryption Setting........................ 431 Backing Up the Encryption Key.......................
  • Page 27 Cover Interposer Tray CI4040 (DC3N) (for 2K/3K Finishers)........... 451 Cover Interposer Tray CI4030 (D3D7)..................451 Finisher SR4080 (D610)......................... 452 Finisher SR4120 (D3CG), Booklet Finisher SR4130 (D3CH)............. 452 Punch Unit Type PU3060 (D706)....................453 Multi Folding Unit FD4000 (D615)....................453 Related SP Codes..........................454 Image Quality Tables............................
  • Page 28 Laser Unit............................467 Charge Corona..........................467 Development............................. 468 Cleaning............................468 Fusing Unit............................469 Paper Feed............................469 Used Toner............................469 Precautions for This Machine........................469 Inner Covers............................469 Proximity Sensor..........................470 PSU Precautions..........................471 Important SP Codes: Machine Information, Servicing................473 Special Tools and Lubricants........................476 Special Tools..............................476 Lubricants..............................
  • Page 29 Microcomputer Board........................503 LCD and Touch Panel........................504 Scanner Unit..............................507 Before You Begin............................507 Scanner Unit Removal ..........................507 Exposure Glass ............................516 Contact Glass............................519 Contact Glass Removal and Reinstallation..................519 Convert from Non-Contact to Contact Scanning Configuration..........523 Contact Glass Cleaning........................525 Lens Block Cover ............................525 Original Width Sensors..........................
  • Page 30 Important SP Codes: Laser Unit........................ 573 Drum Unit................................574 Corona Unit .............................. 574 Corona Grid............................574 Charge Wire............................. 575 Cleaning Pad............................ 576 Corona Wire Cleaning Motor......................577 Corona Power Pack..........................579 Drum................................582 Drum Unit Removal...........................582 Drum Removal...........................583 PTL (Pre-Transfer Lamp)..........................587 QL (Quenching Lamp)..........................589 Potential Sensor............................
  • Page 31 Developer Replacement........................... 633 Replacing the Developer........................633 Re-installing the Development Unit....................638 Initializing the Developer......................... 638 Entrance Seal, Side Seals.........................638 Development Filter.............................641 TD Sensor..............................644 Toner End Sensor............................646 Toner Separation Unit..........................649 Toner Bottle Motor............................ 651 Development Motor..........................656 Development Unit Power Pack......................... 660 Used Toner Collection Unit ........................664 Used Toner Collection Unit Removal....................
  • Page 32 End Thermistor (D225)........................693 Thermostats............................695 Reinstallation............................. 697 Center Thermistor (NC Sensor) (D223/D224)................698 Center Thermistor (NC Sensor) (D225)..................700 Web Cleaning Roller..........................702 Web Unit Disassembly........................702 Re-assembly............................703 Web Unit Re-assembly........................704 Web Motor, Web End Sensor......................... 705 Reinstallation............................. 707 Pressure Roller Cleaning Unit, Cleaning Rollers ..................707 Pressure Roller Cleaning Unit......................707 Pressure Roller Cleaning Roller (D223/D224)................708 Pressure Roller Cleaning Roller (D225)..................709...
  • Page 33 Duplex Unit Removal ..........................746 Re-installation............................746 Adjustments..............................746 Duplex Unit Side-to-Side Adjustment .....................746 Jogger Fence Adjustment......................... 747 Duplex Motors............................747 Duplex Unit Front Cover ........................747 Duplex Inverter Motor........................748 Duplex Jogger Motor........................751 Duplex Transport Motor........................754 Duplex Sensors............................756 Jogger Fence HP Sensor........................756 Duplex Entrance Sensor........................
  • Page 34 Tray 3 Lift Motor..........................783 Right Tray Lock Solenoid........................784 Left Tray Lock Solenoid........................785 Paper Feed Unit Removal ........................787 Paper Feed Motors............................792 Relay Motor............................... 795 Separation Roller Pressure Adjustment....................800 Lift Sensor, Paper End Sensor........................801 Feed Sensor, Vertical Transport Sensor....................803 Pick-up Solenoid............................806 Reverse Release Solenoid........................
  • Page 35 Jam LED D1/E1: Fusing Unit Inner Cover..................850 Paper Feed Adjustments..........................854 Paper Registration..........................854 Buckle Adjustment..........................855 Important SP Codes: Paper Feed......................856 PCBs, HDD..............................858 Before You Begin............................858 Board Locations..........................858 Controller Board Replacement ........................860 Before You Begin..........................860 Controller Board..........................861 Controller Board NVRAM........................
  • Page 36 ADF Covers ...............................901 ADF Front Cover page 901......................901 ADF Rear Cover ..........................903 Feed Cover ............................904 Original Feed Unit ............................905 Pick-up Roller, Transport Belt........................906 ADF Separation Roller ..........................908 Original Registration Sensor........................909 Original Exit Sensor..........................910 ADF Control Board ...........................912 Separation Sensor, Skew Correction Sensor..................913 Original Width Sensor, Interval Sensor....................914 Original Length Sensors..........................915 APS Feeler..............................916...
  • Page 37 Development Unit Fan 1, 2......................940 Duplex Fan............................943 PCU Fan.............................945 Toner Bottle Fan..........................947 Fusing Inner Cover Fan........................952 PSU Fan 1, 2.............................955 AC Drive Board Fan......................... 959 Controller Fan........................... 961 PFU Fan 1, 3, 4..........................962 Main Intake Fan..........................967 Main Exhaust Fan..........................969 Heat Exhaust Fan..........................
  • Page 38 LCD Check............................996 Touch Panel Check........................... 997 Touch Panel Calibration........................998 Multi Touch Calibration........................999 5. Detailed Descriptions Overview..............................1003 General Layout............................1003 Component Layout..........................1005 Bypass Unit............................. 1005 Optics..............................1006 Paper Feed Unit (PFU)........................1006 Electrical Components........................1008 Tandem Tray...........................1009 Around the Drum..........................1010 Sensors, Switches...........................1011 Motors, Fans...........................1012 Transfer, Fusing, Exit Units......................
  • Page 39 Overview............................1027 Shifting the Scanning Position....................... 1029 Scanner Anti-Condensation Heater....................1030 Image Processing............................1031 Image Data Flow............................ 1031 Image Processing............................1032 Image Processing Flow........................1032 Manual Gamma Adjustment......................1033 SP Codes Related to Gamma Adjustments.................. 1033 Print Process (Main Engine Components)....................1035 Laser Unit..............................
  • Page 40 Automatic Setting Operation......................1054 Automatic Process Control......................1056 Development Unit........................... 1056 Development Unit Cross Section....................1056 Toner Supply Unit...........................1058 Development Mechanism......................1059 Inside the Development Unit......................1059 Development Bias.......................... 1060 Development Unit Pressure Release (D225 only)............... 1061 Toner Supply...........................1061 Development Unit Drive and Cooling..................1062 Toner Transport..........................
  • Page 41 Anti-Condensation Heater (Option)..................... 1080 Image Transfer Current Settings....................1080 Fusing Unit............................... 1081 Overview............................1081 More About the Fusing Unit......................1084 Fusing Pressure Mechanism......................1086 Pressure Application (D223/D224 Only).................. 1087 Fusing Safety Devices........................1088 Entrance Guide Height Adjustment....................1089 Fusing Drive Mechanism .......................1090 Temperature Control for Special Paper..................1090 Fusing Temperature Control......................
  • Page 42 Vertical Paper Feed........................1111 Tray 1 (Tandem Tray) ..........................1112 Paper Size Detection........................1112 Tray Movement Mechanism......................1112 Paper Height Detection........................1113 Right Tray Fence Movement Mechanism..................1114 Left Tray Movement ........................1115 Left Tray Lock Mechanism......................1116 Right Tray Lock Mechanism......................1117 Bypass Tray............................. 1119 Bypass Feed Tray Mechanism...................... 1119 Bypass Tray Feed and Separation Mechanism................1119 Paper Stopper Mechanism......................1120 Bypass Tray Paper End Detection Mechanism................
  • Page 43 ADF Unit...............................1143 Overview..............................1143 Specifications..........................1143 Original Size..........................1144 Cross-Section of ADF Unit......................1145 Scanning Sequence........................1146 ADF Components............................1146 Motors.............................1146 Original Pick-up..........................1147 Bottom Plate Lift..........................1148 Original Feed and Separation Mechanism................. 1149 Skew Correction Mechanism......................1150 Original Size Detection......................... 1151 Original Transport..........................1153 Original Scanning..........................1156 Jam Detection Sensors........................
  • Page 44 Handling Data Encryption......................1170 Data Targeted for Encryption......................1170 Precautions About Encryption....................... 1170 Preferences Function (SMC Data Media Storage)................1171 Function Details..........................1171 6. System Maintenance Service Program Mode..........................1175 Enabling and Disabling Service Program Mode................. 1175 Entering SP Mode.......................... 1175 Exiting SP Mode..........................1175 Types of SP Modes..........................
  • Page 45 Uploading/Downloading NVRAM Data.....................1191 Uploading Content of NVRAM to an SD card................1191 Downloading an SD Card to NVRAM..................1192 Updating JavaVM............................1193 Creating an SD Card for Updating....................... 1193 Updating Procedure........................1193 List of Error Messages........................1194 NVRAM Upload/Download........................1197 Uploading NVRAM Data to an SD Card..................... 1197 Downloading NVRAM Data from an SD Card..................1197 UP/SP Data Import/Export........................1199 Overview..............................
  • Page 46 Judgement of ARFU........................1213 Update Process..........................1215 Related SP..............................1218 Package Firmware Update.........................1222 Overview..............................1222 Immediate Update..........................1223 Update at the Next Visit (Reserve)......................1226 How to Set the Machine to Download Firmware Later (RESERVE)..........1226 How to Check if the Firmware Downloaded with RESERVE............1228 How to Install Firmware Downloaded with RESERVE..............
  • Page 47 SC400: Image Development 2........................1269 SC400..............................1269 SC500: Feed, Transport, Duplex, and Fusing..................1273 SC500..............................1273 SC600: Data Communication........................1308 SC600..............................1308 SC700: Peripherals.............................1343 SC700: Peripherals..........................1343 SC800: Overall System..........................1402 SC800..............................1402 SC900: Miscellaneous..........................1457 SC900..............................1457 SC540 to SC545............................1459 Before You Begin............................ 1459 SC540 Fusing web motor error......................1459 Confirm failure to feed......................1459 Web drive gears ........................1460...
  • Page 48 Harnesses..........................1468 SC543 Fusing lamp overheat error 1 (software).................1469 Error duplication........................1469 End thermistor alignment......................1469 End thermistor damage......................1470 AC control board connections....................1471 AC control board........................1471 IOB connection......................... 1472 IOB.............................1472 Harnesses..........................1472 SC544 Fusing lamp overheat error 1: Hardware................1473 Error duplication........................
  • Page 49 Paper Jam Code Display........................1482 Jam Codes and Display Codes......................1482 Main Unit and LCIT: Paper Jam Errors..................1482 ADF: Paper Jam Errors........................1484 Finisher SR4120 Paper Jam Errors....................1485 Finisher SR4130 Paper Jam Errors....................1487 Finisher SR4080 Paper Jam Errors....................1489 Mail Box CS4010 Paper Jam Errors....................1490 Cover Interposer Tray CI4030/CI4040 Paper Jam Errors............
  • Page 50 Output Jogger Units..........................1513 Jogger Width Adjustment Procedure....................1513 Other Problems............................1515 Common Problems..........................1515 Checking Image Quality........................1515 Resolution............................1515 Even Density............................1516 Magnification Errors........................1516 Magnification Error Variation....................... 1517 Reinstralling OCR Unit Type M2......................1518 Fuses................................1520 AC Drive Board............................1520 DHB................................1521 PSU................................1521...

  • Page 51: Product Information

    1. Product Information Machine Configuration Component Layout...
  • Page 52 1. Product Information Part Part Entrance Roller (ADF) Feed Roller (Paper Tray) Feed Belt (ADF) Separation Roller (Paper Tray) Separation Roller (ADF) Pick-up Roller (Paper Tray) Pick-up Roller (ADF) Universal Tray (Tray 3) CIS (Contact Image Sensor) Universal Tray (Tray 2) Original Feed-in Tray Tandem Tray (Tray 1) Exposure Glass...

  • Page 53: Paper Path (With Cover Interposer Tray)

    Machine Configuration Paper Path (With Cover Interposer Tray) Part Proof Exit Tray Cover Sheet Path Original Path By-pass Tray LCT Feed Vertical Transport Path Finisher Exit Tray 2 Finisher Exit Tray 1...

  • Page 54: Paper Path (With 9-Bin Mailbox)

    1. Product Information Paper Path (With 9-Bin Mailbox) Part Original Paper Path Vertical Transport Path LCT Feed Selected Trays Turn Gates Mailbox Paper Path...

  • Page 55: Drive Layout

    Machine Configuration Part Junction Gate Junction Gates Drive Layout Part Scanner Motor Drum Motor Fusing/Exit Motor...
  • Page 56 1. Product Information Part Registration Motor Toner Collection Motor Tray 3 Paper Feed Motor Tray 2 Paper Feed Motor Lower Relay Motor Tray 1 Paper Feed Motor By-pass Motor Development Motor...

  • Page 57: Machine Codes And Peripherals

    Machine Codes and Peripherals Machine Codes and Peripherals Peripheral Units Unit Mainframe D223/D224/D225 A3/11" x 17" Tray Type 9001* D482 Tab Sheet Holder 9002* B499 LCIT 4040 D3D6 81/2" x 11" Paper Size Tray Type 9002 B474 Copy Tray 9002 B756 Multi-Folding Unit FD4000 D615...

  • Page 58: Other Options

    1. Product Information Unit Output Jogger Unit Type 9002B B513 Cover Interposer Tray CI4030 D3D7 Finisher SR4120 D3CG Punch Unit PU3060 SC* D706 Punch Unit PU3060 EU* D706 Punch Unit PU3060 NA* D706 Booklet Finisher SR4130 D3CH Cover Interposer Tray CI4040 DC3N Mail Box CS4010 D708...

  • Page 59: Mainframe Options: Internal

    Machine Codes and Peripherals Mainframe Options: Internal Unit Connection Optional Counter Interface Unit Type M12 B870 Main machine Controller Options: I/F Slots Unit Connection Copy Connector Type M25 D3D3 Controller Box I/F Slot Extended USB Board Type M19 D3BS Controller Box I/F Slot File Format Converter Type M19 D3BR Controller Box I/F Slot...

  • Page 60: Fax Options

    1. Product Information Fax Options Unit Connection Fax Option Type M25 D3D5 Controller Board G3 Interface Unit Type M25 D3D5 Controller Board Fax Connection Type M25 D3D4 SD Card Fax Memory Unit Type M25 64MB D3D5 Fax Board...

  • Page 61: Specifications

    Specifications Specifications See "Appendices" for the following information: • General Specifications • Supported Paper Sizes • Software Accessories • Optional Equipment Specifications...

  • Page 62: Guidance For Those Familiar With Predecessor Products

    1. Product Information Guidance for Those Familiar with Predecessor Products The D223/D224/D225 succeeds the D131/D132/D133 series. If you have experience with the previous products, the following information will be of help when you read this manual. Differences from Predecessor Products General D131/D132/D133 D223/D224/D225...

  • Page 63: Important Changes

    Guidance for Those Familiar with Predecessor Products Bank 52 to 169 g/m 52 to 256 g/m Heavier paper Duplex 64 to 169 g/m 52 to 256 g/m Heavier paper Bypass 52 to 216 g/m 52 to 300 to g/m Heavier paper Sleep mode 1.1 W Less power...
  • Page 64 1. Product Information Bypass The bypass tray has a new paper length sensor used to detect the length of the paper loaded in the bypass tray. The bypass motor (a stepper motor in the previous machine) has been replaced with a DC motor. Also, the motor can no longer be serviced from the back of the machine.
  • Page 65 Guidance for Those Familiar with Predecessor Products Controller The controller is new. The faceplate of the previous machine [A] is on the right, the faceplate of this machine [B] is on the left. Both machines have the same number of SD cards slots (2) and I/F slots (2). The I/F slots of this machine are clearly labeled "Tandem"...
  • Page 66 1. Product Information The controller box has a cover like the previous model, but there are fewer screws to take off in order to remove the controller box cover. There are only two screws on the face and two on the side. The controller box cover is much easier to remove.
  • Page 67 Guidance for Those Familiar with Predecessor Products The Cover Interposer Tray CI4030 (D3D7) is new and designed for the Finisher 4080 (D610). The other tray, Cover Interposer Tray CI4040 (DC3N) can be used with either the Finisher SR4120 (D3CG) or Booklet Finisher SR4130 (D3CH). With the previous machine there was only one cover interposer tray available for all three finishers.
  • Page 68 1. Product Information Duplex unit. The junction gate solenoid [A] has been reinforced to reduce junction gate chatter that can occur when heavy paper is being used. Also, the transport motor, a stepper motor in the previous machine, has been replaced with a DC motor [B].
  • Page 69 Guidance for Those Familiar with Predecessor Products Drum fan. This was the main intake fan on the previous machine. Main intake fan. This was the drum fan on the previous machine. Main exhaust fan. This fan and duct are new. Main heat exhaust fan.
  • Page 70 1. Product Information LD unit With the previous machine, a label was attached to the new LD unit with SP settings (SP2115-001 to 005) that had to be entered manually from the operation panel. However, with this machine, you need only execute SP2110-005 once to automatically download all the settings from the machine for the new LD unit.
  • Page 71 Guidance for Those Familiar with Predecessor Products Laser unit The scanner unit must be removed in order to service the laser unit below it. NC sensor The fusing unit has a new NC sensor. The NC sensor [1] is mounted above the heating roller [2] to monitor the temperature of the roller.
  • Page 72 1. Product Information Operation panel This machine has adopted the new Smart Operation Panel. PCB layout. The layout of the main boards on the back of the machine has changed. In this machine the BICU (formerly BCU) and IOB have swapped positions. The BICU is in the controller box next to the controller board.
  • Page 73 Guidance for Those Familiar with Predecessor Products PFU motors The paper feed motor of the D225 is no longer an external motor. It is encased in the PFU unit, just like the D223/D224. Also, the STM (stepper motor) has been replaced with a DCM (DC motor). Paper jam handling New LEDs are provided on the inner covers on the paper path.
  • Page 74 1. Product Information Every inner cover over the paper path, like the fusing unit cover [A] and vertical inner cover [B], has an LED harness that must be carefully disconnected before the cover can be removed. Inner covers must be removed with care in order to prevent damage to these connectors and harnesses.
  • Page 75 Guidance for Those Familiar with Predecessor Products Power cord. The power cord is new. It is not permanently attached to the machine, so it must be connected and locked in place with a bracket held by one screw. Rotation count sensor A knob rotation count sensor has been added at the front left corner of the fusing unit.
  • Page 76 1. Product Information STM to DCM Most of the STM motors (Stepper Motors) of the previous machine have been replaced with DCM motors (DC Motors). Scanner SIOB There is no SIOB (Scanner Interface Board) in the scanner unit, the driver that controlled the sensors and scanner motor in the previous machine.
  • Page 77 Guidance for Those Familiar with Predecessor Products Scanner unit The exposure lamp has been replaced with a pair of exposure LEDs [1] and [2]. The 2nd LED doubles the intensity of the light so the CMOS element can pick up and produce a better image. TD sensor A new 24V TD sensor in the development unit is mounted on a longer bracket provided with bracket clamps for the sensor harness.

  • Page 78: Unit And Option Name And Number Changes

    1. Product Information Temperature sensor A temperature sensor near the drum unit monitors the internal temperature of the machine to ensure cool and efficient operation. Unit and Option Name and Number Changes The main peripherals and other options are essentially the same as the same items for the predecessor machines.
  • Page 79 Guidance for Those Familiar with Predecessor Products D131/D132/D133 D223/D224/D225 Mainframe (D131/D132/D133) Mainframe (D223/D224/D225) 8 1/2"x14" Paper Size Tray Type 9002 81/2" x 11" Paper Size Tray M25 (B474) (B474) A3/11" x 17" Tray Type 9001 (D482) A3/11" x 17" Tray Type M25 (D615) Copy Tray Type 9002 (B756) Cover Interposer Tray CI4000 (D614) Cover Interposer Tray CI4040 (DC3N)

  • Page 80: Mainframe Options: External

    1. Product Information Mainframe Options: External D131/D132/D133 D223/D224/D225 ADF Handle (D593) Card Reader Bracket (B498) Key Counter Bracket Type 1027 (B452) Key Counter Bracket 1027 (B452) NFC Card Reader Type M19 (D3BS) USB2.0/SD Slot Type C (D464) Discontinued* USB slot built into new operation panel Mainframe Options: Internal D131/D132/D133 D223/D224/D225...

  • Page 81: Controller Options: Sd Cards, Built-In

    Guidance for Those Familiar with Predecessor Products D131/D132/D133 D223/D224/D225 IEEE1284 Interface Board Type A (B679) IEEE 1284 Interface Board Type M19 (D3C0) IEEE802.11a/g Interface Unit Type J (D377) IEEE 802.11 a/g/n Interface Unit M19 (B3BR) IEEE802.11g Interface Unit Type K (D377) Extended USB Board Type M19 (D3BS) Controller Options: SD Cards, Built-in •...

  • Page 82: Hdd

    1. Product Information The Enhanced Security HDD Option Type M10 (D792) is an HDD. Fax Options • Changes are marked in bold in the right column. Fax Options D131/D132/D133 D223/D224/D225 Fax Option Type 9002 (D619) Fax Option Type M25 (D3D5) G3 Interface Unit Type 9002 (D619) G3 Interface Unit Type M25 (D3D5) Fax Connection Unit Type E (D621)

  • Page 83: Installation

    2. Installation Installation Requirements Operating Environment 1. Temperature Range • Recommended: 15°C to 25°C (59°F to 77°F) • Possible: 10°C to 32°C (50°F to 90°F) 2. Humidity Range: • Recommended: 30% to 70 %RH • Possible: 15% to 80% RH (27 °C 80%, 32 °C 54%) 3.

  • Page 84: Machine Level

    2. Installation • Directly exposed to heat from a heater 8. Do not place the machine where it will be exposed to corrosive gases. 9. Do not install the machine at any location over 2,000 m (6,500 feet) above sea level. 10.

  • Page 85: Dimensions

    Installation Requirements Dimensions Power Requirements • Make sure that the wall outlet is near the main machine and easily accessible so it can be unplugged in an emergency. • Make sure the plug is firmly inserted in the outlet. • Avoid multi-wiring. •...
  • Page 86 2. Installation • Never place anything on the power cord. Input voltage level North America 120 V, 60 Hz: 20 A or more Europe/Asia 220 V to 240 V, 50 Hz/60 Hz: 10 A or more Taiwan 110V, 60 Hz, 20A or more Permissible voltage ±10% fluctuation...

  • Page 87: Main Machine

    Main Machine Main Machine Accessory Check Check the accessories and their quantities against this list: Description Q’ty 1. Model Name Decal (-29 Only) 2. Operation Instructions (-17, -19, -21, -29, -57 Only) 3. Leveling Shoes (Front) 4. Decal – Paper Size 5.

  • Page 88: Installation Flow

    2. Installation Installation Flow Step Before Power On Remove Tapes and Shipping Materials Attach Power Cord to Machine Remove Development Unit Load Developer Re-install Development Unit Set Toner Bottle Set Tandem Tray for A4 or LT Paper Level the Machine Attach Cleaning Cloth Holder Connect Drum Heater, Tray Heater (Optional) Load Paper, Attach Decals...

  • Page 89: Installation Procedure

    Main Machine Installation Procedure Remove Tapes and Shipping Materials 1. Remove the cover [A]. 2. With four people, one person at each corner of the machine, lift the machine slightly while a 5th person slides the pallet [B] from under the machine. 3.
  • Page 90 2. Installation 4. Remove tape and cardboard strips from rear [A] and left side [B]. 5. Remove tapes from the surface of ADF [A]. 6. Open ADF [B].
  • Page 91 Main Machine 7. Remove all tape and packing material inside the ADF [A]. 8. Close ADF [B]. 9. Remove tapes under original output tray [A]. 10. Remove accessory decals [B]. 11. Raise the ADF, and then remove cover sheet [A].
  • Page 92 2. Installation 12. Raise the ADF and remove tape [A]. 13. Pull the sheet [B] out from behind the white plate. The sheet is white and difficult to see. The tape is a reminder to pull this sheet. 14. Remove tape [A] above rear scale.
  • Page 93 Main Machine 15. Remove tape [A] from left scale of the exposure glass. 16. Remove protective sheet from operation panel display. 17. Open the front door. 18. Remove tape and sheets at [1], [2], [3], [4].
  • Page 94 2. Installation 19. Swing open the toner bottle holder [A]. 20. Disconnect PCU inner cover [A]. 21. Rotate lever C1 [B] down. The lowers the transfer belt unit.
  • Page 95 Main Machine 22. Disconnect PCU inner cover at [1], and then disengage its corner tab at [2]. 23. Raise PCU inner cover [A] and then remove it.
  • Page 96 2. Installation 24. Remove bracket, wire, red tag [A]. 25. Remove plug, wire, red tag [A]. 26. Open the bottom tray.
  • Page 97 Main Machine 27. Remove factory data sheet from the right side of the bottom tray. This is a list of the default settings of important SP codes. 28. Open the front door [A]. 29. Fold the data sheet [B] and store it as shown for future reference.
  • Page 98 2. Installation 30. Inside the tandem tray [A], remove tape and spacer [1]. 31. Remove tape and cushion [2]. 32. Remove red tag, wire, and bracket [3]. 33. Remove tape and packing from the face of right tray [A].
  • Page 99 Main Machine 34. Open Tray 2 [A], and then remove tape and red tag on the corner. 35. Remove packing on the right, and then unpack it. This is the power cord, bracket, and bracket screw.

  • Page 100: Attach Power Cord To Machine

    2. Installation 36. Remove packing on the left, and then unpack it. These are [1] Front leveling shoes, [2] rear leveling shoes, [3] glass cleaning cloth and cloth holder. Attach Power Cord to Machine 1. Locate the power connection point [A] on the left rear corner of the main machine. 2.

  • Page 101: Remove Development Unit

    Main Machine • Do not connect the power cord until you are instructed to do so. Remove Development Unit 1. If the LCIT is connected to the right side of the machine, disconnect it and pull it away. 2. Prepare a clean, flat surface for the development unit. 3.
  • Page 102 2. Installation • A washer is attached to the shuttle cover screw in order to prevent the screw from falling into the machine. Turn the screw counter-clockwise only enough turns to remove it. If you loosen the screw too much the washer will fall into the machine. 1.
  • Page 103 Main Machine 4. Push the front door slightly to the right, and then swing the holder out as far as it will go. • The door must be completely open. If it is not, then it will block removal of the development unit.
  • Page 104 2. Installation 7. Remove development unit faceplate. 8. Raise the toner supply pipe shutter to close the pipe.
  • Page 105 Main Machine 9. On the right [A] disconnect the development unit. 10. Slip the development unit [A] to the right. 11. Push the development unit [A] slightly to the right, and then pull the unit [B] straight out of the machine.

  • Page 106: Load Developer

    2. Installation 12. Lay the development unit on the prepared surface. Load Developer 1. At the front end of the unit, disconnect the pressure release tube. • Only the D225 Model has this pressure release tube. This step is not required for the D223/ D224 models.
  • Page 107 Main Machine 2. Disconnect the toner hopper. 3. Rotate the toner hopper slightly as you lift it. 4. Remove the toner hopper and set it aside. 5. Shake the developer pack to loosen the developer inside. 6. Cut off the top of the pack.
  • Page 108 2. Installation 7. Save the top with the lot number embossed on it. You will need to enter this number later with SP2963-002. 8. While turning the knob slowly in the direction of the arrow as shown below, move the open end of the pack side to side as you continuously pour developer into the open slot of the development unit.

  • Page 109: Re-Install Development Unit

    Main Machine Re-install Development Unit Pay attention to these important points as you re-install the development unit. • To re-assemble the top and bottom half of the development unit, first allow the bottom half [A] to tip slightly forward. • Hold the top half [B] (toner hopper) over the bottom half, set the cutouts on the ends of the shaft below, and then slowly rock the top half forward [C] so the holes are aligned.
  • Page 110 2. Installation • Slip slightly to the right as you push it slowly back into the machine. • Push the development unit in until it stops, and then push it to the left. • You should see the pin through the oval hole as shown below. This means the unit is locked in the correct position.
  • Page 111 Main Machine • The horizontal pin must be through the hole and overlapping the plate as shown below on the left. • If the pin does not slide over the plate as shown above, turn the front gear of the development unit counter-clockwise and try again.
  • Page 112 2. Installation • You must remember to lower the supply pipe shutter so the pipe is open. • The shutter must be down. If it remains up, you will not be able to close the toner bottle holder and the front door. •...

  • Page 113: Set Toner Bottle

    Main Machine Set Toner Bottle 1. Rotate the bottle at least 10 times to make sure that the toner inside is loose. 2. Remove toner bottle cap. 3. Swing out the toner bottle holder as shown [1] 4. Set the toner bottle in the holder [2], push it in until you hear a click, and then turn it clockwise [3] to lock it in place.

  • Page 114: Set Tandem Tray For Lt Or A4 Paper

    2. Installation 5. Swing the toner bottle and holder to the left against the front of the machine. Set Tandem Tray for LT or A4 Paper Before You Begin The tandem tray (Tray 1) can accommodate either letter (LT) or A4-size paper, depending on how the side fences are set.
  • Page 115 Main Machine There are two trays in the tandem tray, a left tray [A] and a right tray [B]. If you want to change the setting to LT or A4, you need to do five adjustments. • Change the positions of the front side fences [1] in both the left and right tray. •...
  • Page 116 2. Installation 4. Lift the front fence [A] out of the rear slot (LT) and then insert it in the front slot (A4). 5. Fasten the front fence[B]. 6. Remove the screw of the right tray rear fence [A]. 7. Lift the rear fence [B] out of the front slot (LT) and then insert it in the rear slot (A4). 8.
  • Page 117 Main Machine 9. Re-attach the faceplate of the right tray. Left Tray Side Fences 1. Disconnect Tray 1 faceplate [A].
  • Page 118 2. Installation 2. Remove the Tray 1 faceplate. 3. Disconnect the motor cover: • Right [A]. • Left [B] 4. Remove motor cover [A].
  • Page 119 Main Machine 5. Pull the left tray out until it stops. 6. Disconnect the left tray from the left rail [A]. 7. Pull left tray [B] slightly more until it stops. 8. Disconnect • Left [A] of rear side fence. •...
  • Page 120 2. Installation 9. Disconnect right end [A] of rear side fence. 10. Lift the rear side fence out of the front slot (LT), and then set it in the rear slot (A4).
  • Page 121 Main Machine 11. Re-attach the screw at the left end of the side fence, and then re-attach the screws at the right end of the side fence ( x4). 12. Disconnect the marker plate at LT, and then reset the screw at A4. This serves as a reminder for the paper setting of the tandem tray.
  • Page 122 2. Installation 14. Disconnect left side [A] of the left tray front fence. 15. Disconnect the base of the front fence from the base of the tray [B]. 16. Lift the front side fence out of the rear slot (LT), and then set it in the front slot (A4).
  • Page 123 Main Machine 17. Re-fasten the front fence ( x4). 18. Set the motor cover over the front side fence, and then re-attach the left side [A] of the cover. 19. Re-attach right side of the cover [B]. 20. Set the base of Tray 1 faceplate [A], and then re-attach it to the tray [B] ( x3).
  • Page 124 2. Installation Adjust Left Tray Paper Position for LT/A4 1. The left tray paper sensor is below the rear plate [A] in the left tray. 2. Remove rear plate [A].

  • Page 125: Level The Machine

    Main Machine 3. Remove the screw of the sensor bracket, and then slide the bracket from the left (LT) to the right (A4). 4. Re-attach and tighten the screw. Level the Machine 1. There are two pairs of shoes for leveling the machine, the front shoes [1] (attached brackets) and rear shoes [2].
  • Page 126 2. Installation 3. Position the front shoes (with the brackets) under the front of the machine. 4. Run the brackets down with your fingers, and then tighten with the accessory wrench. 5. At each rear corner, run the hex screw down with your fingers, and then slide a shoe under the screw.

  • Page 127: Attach Cleaning Cloth Holder

    Main Machine 8. Place a level on the front edge of the exposure glass [A], and then on the right edge of the exposure glass [B]. 9. The machine should be level: • Front to back: Within ±5 mm (0.2") of level •...

  • Page 128: Connect Drum Heater, Tray Heater (Optional)

    2. Installation Connect Drum Heater, Tray Heater (Optional) The drum heater and tray heater prevent moisture from gathering on the surface of the drum and in the paper feed trays. Connect these heaters where humidity is extremely high or where there are wide and rapid changes in temperature that could form condensation inside the machine.
  • Page 129 Main Machine 3. Remove rear upper cover 4. Now, remove the rear lower cover. 5. At the right, lower corner [A]: • Loosen shoulder screw [1].
  • Page 130 2. Installation • Remove screw [2]. 6. At the left, lower corner [B]: • Loosen shoulder screw [3]. • Remove screw [4]. 7. Remove the rear lower tray. 8. At the left lower corner [A], locate the heater connectors [1] and [2].
  • Page 131 Main Machine 9. Free the heater connectors [1] and [2] [A], and then locate their connection points on the corner of PSU [B]. 10. Connect both harnesses.

  • Page 132: Load Paper, Attach Decals

    2. Installation 11. If you want the anti-condensation heaters to remain on at all times, detach the third harness from the bundle, then connect to the same PCB at CN930. Load Paper, Attach Decals Paper Size Decals 1. Load the paper trays. 2.

  • Page 133: Attach Name Plate

    Main Machine 3. Attach the ‘load originals face-up’ reminder to the original output tray. Attach Name Plate 1. Attach the nameplate to the center of the front door.

  • Page 134: Initialize Toner And Process Control Settings

    2. Installation Initialize Toner and Process Control Settings 1. Make sure that the power cord is attached to the right lower corner of the main machine. 2. Plug the power cord into the power source. • There is no power switch on the operation panel of this machine. 3.

  • Page 135: Check Image Quality And Settings

    Main Machine • The machine is waiting for entry of the Supervisor and Administrator passwords. • It is the responsibility of the site supervisor and system administrator to set these passwords. • The Home menu will not display until these passwords have been set. However, you can bypass this screen to complete the installation.

  • Page 136: Important Notice On Security Issues

    2. Installation SP5812-001 Service Telephone Number Settings. Enter the contact number of the customer engineer. This is the number displayed when a service call is issued. SP5841-001 Supply Name Setting – Toner Name Setting: Important Notice on Security Issues In order to increase the security of the MFP, and to ensure that the customer sets the administrator password, an administrator set/change prompt display appears the first time the machine is turned on.

  • Page 137: Password Setting Procedure

    Main Machine • SP5-755-002 allows the service technician to skip this screen temporarily and continue the installation procedure without setting an administrator password. • However, the Program/Change Administrator screen appears every time the machine is cycles off/on if the password has not been set. Password Setting Procedure Follow this procedure to set the passwords.

  • Page 138: Auto Remote Firmware Update Settings

    2. Installation 1. Input the password. 2. Press [OK]. 3. Confirm the password. 4. Press [OK]. 5. Cycle the machine off/on. Auto Remote Firmware Update Settings Specify ARFU settings as required. Operating Conditions: • Use the machine in an environment where it can be connected to the Internet. •...
  • Page 139 • If the access to the external server is restricted, request the network administrator (customer) to permit the following FQDN name for communication: • - FQDN: p-rfu-ds2.support.ricoh.com Configuration Procedure In User Tools > Machine Features > System Settings > Interface Settings, specify the IP address, Subnet, Gateway, and DNS settings according to the user’s network...
  • Page 140 2. Installation • SP5-886-114 (AutoUpdateProhibitEndHour) • Default: 17 • SP5-886-120 (AutoUpdateProhibitDayOfWeekSetting) Default: 0x00 Set the bits for the days of the week to prohibit updating. Prohibited (Monday - Sunday): Bit 7 Monday: bit 6 Tuesday: bit 5 Wednesday: bit 4 Thursday: bit 3 Friday: bit 2 Saturday: bit 1...
  • Page 141 Main Machine Click "Auto Firmware Update". In the applicable items, specify the times and days of the week to prohibit updating. Select the check boxes of the applicable days of the week to prohibit updating on that...
  • Page 142 2. Installation Checking the ARFU Connection Enter the SP mode. Press [Firmware update]. Press [Update]. Press [Execute update]. • ”Execute update” appears even if @Remote connection has not been established. • If an error code appears when you click “Execute update”, the machine is in the following status. Error code Status The machine in operation for printing, etc.

  • Page 143: Security Settings

    Main Machine Checking the Result from the Firmware Update Setting Enter the SP mode. Press [Firmware update]. Press [Update]. Press [Update Package Information]. If the firmware package is the same as the one on the global server, the update was completed successfully.

  • Page 144: Transporting The Machine

    2. Installation 5. To avoid damage to the machine, avoid tipping and excess vibrations. Transporting the Machine • When moving the machine, never push on the ADF. • Pushing on the ADF could damage it or throw it out of alignment, causing problems with scanning and copying.
  • Page 145 Main Machine Item SP No. Function Password request cancel 5755-2 Cancels the password request screen and allows you to continue with the machine installation as long as the machine remains on Service tel. number 5812-1 Enter the contact number of the customer engineer.

  • Page 146: Drum Heater (Option)

    2. Installation Drum Heater (Option) Accessories The drum heater is an option for the main machine. Check the accessories and their quantities against this list. Description Q"ty 1. Drum Heater 2. Screws M3x6 Installation Install Drum Heater 1. Open the front door, and then swing the toner bottle holder to the right. 2.
  • Page 147 Drum Heater (Option) 4. Remove drum unit [A]. page 582 5. Remove transfer belt unit [B]. page 674 6. The drum heater harness [A], shown here on the back of the machine behind the IOB, is pre- installed at the factory before shipping. 7.
  • Page 148 2. Installation 8. If lever C1 is down to the left, turn it to the right. 9. Unfasten stay [A]. 10. Remove the stay. Keep this screw.
  • Page 149 Drum Heater (Option) 11. Lay the stay on a flat, clean surface as shown with rear end [A] to the right. 12. Set the drum heater next to the stay with the connector [B] to the right. 13. Set the heater on the stay, and fasten it with screws. 14.
  • Page 150 2. Installation 16. Insert the rear end of stay [A] into the cutout inside the machine. 17. At the front [B] fasten the stay. 18. Connect the heater at the rear...

  • Page 151: Connect The Drum Heater

    Drum Heater (Option) 19. Re-install: • Transfer belt unit • Drum unit • Charge corona unit • Development unit Connect the Drum Heater The harness for the drum heater is installed at the factory before shipping. 1. Remove the rear lower cover. page 483 2.
  • Page 152 2. Installation • This dual connector shared by both the drum heater harness and scanner harness. • If the scanner heater has been installed, this connector will already be connected to the DHB. • When the single connector is plugged in, both the drum heater and scanner heater are connected.

  • Page 153: Scanner Heater (Option)

    Scanner Heater (Option) Scanner Heater (Option) Accessories The scanner heater is an option for the main machine. Check the accessories and their quantities against this list. Description Q"ty 1. Scanner Heater 2. Screws M3x6 Installation Install Scanner Heater 1. Raise the ADF. 2.
  • Page 154 2. Installation 5. Remove the rear scale. 6. Remove the left exposure glass edge cover. 7. Remove the exposure glass.
  • Page 155 Scanner Heater (Option) 8. At the right front corner of the machine [A] turn the scanner motor belt and move the 1st scanner unit to the left edge of lens cover [B]. 9. With the harness on the left, slide scanner heater [A] under the 2nd carriage, and then arrange it parallel to the back of the scanner unit [B].
  • Page 156 2. Installation 10. Pull the heater harness through the left side of the scanner unit. 11. Disconnect the left edge cover [A], and then remove it, so you can see cut-out [B]. 12. Insert a screwdriver into the cut-out [A], and then loosely fasten the left end of the heater. 13.

  • Page 157: Connect The Scanner Heater

    Scanner Heater (Option) 15. On the left side of the scanner unit, clamp the heater harness, and then connect it to the harness pre-installed on the side of the machine. Connect the Scanner Heater 1. Remove the rear lower cover. page 483 2.
  • Page 158 2. Installation If the connector is already plugged into the DHB as shown below, you are finished. • This dual connector shared by both the drum heater harness and scanner harness. • If the drum heater has been installed, this connector will already be connected to the DHB. •...

  • Page 159: A3/11"X17" Tray Type 9001 (D482)

    A3/11"x17" Tray Type 9001 (D482) A3/11"x17" Tray Type 9001 (D482) Accessory Check Check the accessories and their quantities against this list: Description Q’ty 1. A3/DLT Tray 2. Short connector 3. Page size decals Installation Procedure • Switch the machine off and unplug the machine before starting the following procedure. 1.
  • Page 160 2. Installation 3. Draw out the tandem tray [A] completely to separate the left and right sides of the tray. 4. Push in the right tandem tray [B]. 5. Remove the left tandem tray [A]. Keep these screws.
  • Page 161 A3/11"x17" Tray Type 9001 (D482) 6. Remove the front cover [A].. 7. Remove the right tandem tray [A] ( x 2). Keep these screws.
  • Page 162 2. Installation 8. Connect the short connector [A] to the left tandem tray terminal [B]. 9. Install the A3/DLT tray [A] on the right rail [B], center rail [C], and left rail [D]. Use the screws that you removed earlier. •...

  • Page 163: Lcit Rt4040 (D3D6)

    LCIT RT4040 (D3D6) LCIT RT4040 (D3D6) Accessory Check Check the accessories and their quantities against this list: Description Q’ty 1. Upper docking pins (grooved) 2. Lower docking pin (not grooved) 3. Flat-head shoulder screw - M4 x 6 4. Paper Set Decal - Installation Instructions •...

  • Page 164: Installation

    2. Installation Installation Removing Tape 1. Remove all tape and packing material on front [A] and right side [B]. 2. Remove tape and cardboard from [A] and right side [B]. Be sure to retrieve the accessories packed in the plastic bag taped to the rear panel.
  • Page 165 LCIT RT4040 (D3D6) 3. Open the unit. 4. Remove tape from around the lift plate [A] and under the top cover [B]. 5. Inspect the unit outside, inside [A], and under the cover [B] to confirm that there is no tape, cardboard, or scraps remaining in the LCIT.

  • Page 166: Preparing The Main Machine

    2. Installation Preparing the Main Machine • Switch the machine off and unplug the machine before starting the following procedure. 1. On the right side of the main machine, remove the LCIT installation cover. 2. Remove the LCIT connector cover. 3.

  • Page 167: Docking The Lcit

    LCIT RT4040 (D3D6) 4. Select the two grooved docking pins [A], and then attach them at [B]. 5. Attach the remaining docking pin at [C]. Docking the LCIT 1. Slowly, push the left side of the LCIT against the side of the main machine.
  • Page 168 2. Installation 2. If you need to release the LCIT and try again, push the release button and then pull the LCIT away from the side of the main machine. 3. Open the top cover of the LCIT.
  • Page 169 LCIT RT4040 (D3D6) 4. Remove the right panel [A]. 5. Look inside the LCIT and locate the hole for the shoulder screw.
  • Page 170 2. Installation 6. Set the flat-head shoulder screw [A] on the tip of a screwdriver, and then fasten in the hole behind panel [B]. • This screw locks the release button on the front of the LCIT. • In order to separate the LCIT from the main machine, you will need to first remove this screw. •...

  • Page 171: Paper Size Adjust And Setting

    LCIT RT4040 (D3D6) 8. Plug the LCIT power cord into the connector. Paper Size Adjust and Setting The side fences [A] and [B] can be adjusted for different paper sizes: • A4 LEF • B5 LEF • LT LEF...
  • Page 172 2. Installation 1. Open the top cover of the LCIT.
  • Page 173 LCIT RT4040 (D3D6) 2. Remove the right panel of the LCIT. 3. If the LCIT is connected to the main machine, remove the lock screw.
  • Page 174 2. Installation 4. Press the release button on the front of the LCIT [A], and then pull the LCIT slightly away from the side of the main machine, but do not disconnect the LCIT I/F cable. 5. If the LCIT is disconnected, connect the I/F cable to the main machine [A], and then turn the machine on.
  • Page 175 LCIT RT4040 (D3D6) 7. Confirm that the main machine is on, and that the LCIT is connected to the main machine. 8. To lower the tray plate, cover photosensor [1] with your left hand, and then press and hold down button [2].
  • Page 176 2. Installation 10. Unfasten and remove rear fence [A]. 11. Unfasten and remove front fence [A].

  • Page 177: Lcit Heater (Option)

    LCIT RT4040 (D3D6) 12. Set the bottom edge of each side fence into the slot for the paper size that you want you load into the LCIT 13. Set the notches at the top of each side fence at the name of the paper size. 14.

  • Page 178: Installation

    2. Installation Description Q’ty 7. Flat Clamps 8. LCIT Heater Harness Installation LCIT Side 1. Turn the machine off. 2. Open the top cover of the LCIT.
  • Page 179 LCIT RT4040 (D3D6) 3. Remove the right panel of the LCIT. 4. If the LCIT is connected to the main machine, remove the lock screw.
  • Page 180 2. Installation 5. Press the release button on the front of the LCIT [A], then then pull the LCIT slightly away from the side of the main machine, but do not disconnect the LCIT I/F cable. 6. If the LCIT is disconnected, connect the I/F cable to the main machine [A], and then turn the machine on.
  • Page 181 LCIT RT4040 (D3D6) 8. Turn the machine on, and confirm that the LCIT is connected to the main machine. 9. To lower the tray plate, cover photosensor [1] with your left hand, and then press and hold down button [2]. 10.
  • Page 182 2. Installation 11. Unfasten and remove rear fence [A]. 12. Unfasten and remove front fence [A].
  • Page 183 LCIT RT4040 (D3D6) 13. After both fences have been removed, close the top cover [A]. 14. The lift motor will switch on and raise the tray plate to the up position [B]. This will take about 30 sec. 15. At the left bottom edge of the LCIT, remove the stay. 16.
  • Page 184 2. Installation 18. Remove the positioning plate. 19. Attach the clamps to the bottom of the LCIT.
  • Page 185 LCIT RT4040 (D3D6) 20. Set the LCIT heater, and then pass the heater harness under the rear side of the shaft. 21. Set accessory bracket [A], position the bracket [B] over the harness, and then fasten it.
  • Page 186 2. Installation 22. Fasten the heater with the accessory screws. 23. Insert the bayonet connector [1] into the cut-out in the frame. 24. Lay the harness in the open clamps [2] and then close the clamps.
  • Page 187 LCIT RT4040 (D3D6) 25. Re-assemble the LCIT in reverse order. This completes preparation on the LCIT side. Main Machine Side • The machine is shipped from the factory with main machine upper and lower paper bank heaters (standard) disconnected. • These heaters are pre-installed but may or may not be connected in your machine. However, the procedure below starts with the main machine tray heaters connected.
  • Page 188 2. Installation • The upper heater harness has the box receptacle [1] at the top and bayonet connector [2] at the bottom. 5. One end of the LCIT harness has two connectors: box receptacle [1] and bayonet connector [2]. 6. Disconnect the main machine upper heater harness.
  • Page 189 LCIT RT4040 (D3D6) 7. Insert the bayonet connector [1] of the connector pair on the end of the LCIT heater harness to the box receptacle [2] of the upper heater harness. 8. Insert the bayonet connector [3] of the upper heater harness into the box receptacle [4] of the LCIT heater harness pair.
  • Page 190 2. Installation 11. Clamp the connectors [A] as shown. 12. Raise the heater harness and clamp it [B]. 13. Raise the LCIT heater harness, and clamp it at the top edge of the AC drive board [A]. 14. Raise the LCIT heater harness through the hole in the frame [B].
  • Page 191 LCIT RT4040 (D3D6) 15. Clamp the LCIT heater harness behind the IOB. 16. Behind the IOB, push the LCIT heater harness behind the stay [A], and then pull it out under flywheel [B].
  • Page 192 2. Installation 17. Pull the LCIT harness below the flywheel [A] and then clamp it [B]. 18. Disconnect stopper [A] on the base of the toner collection pump. 19. Pass the harness under arm [B] of the base, and then re-fasten the stopper.
  • Page 193 LCIT RT4040 (D3D6) 20. Clamp the harness at [A], and then push it out the right side of the main machine [B]. 21. Pull the harness out of the main machine, and then clamp it. This completes preparation on the main machine side. Docking 1.
  • Page 194 2. Installation 2. Hold the ground wire straight up, and then fasten it tightly. 3. Measure the positions for the flat clamps on the left side of the LCIT. 4. Attach the flat clamps to the left face of the LCIT.
  • Page 195 LCIT RT4040 (D3D6) 5. Remove the left upper plate from the LCIT. 6. Pass the end of the harness through saddle clamp [A] and then clamp it. 7. Re-attach the left upper plate [B]. 8. Connect the harness from the main machine to LCIT heater. 9.
  • Page 196 2. Installation 10. Connect the ground wire to the side of the main machine near the joint connector, at about a 45 degree angle as shown. 11. Push the LCIT [A] close to the side of the main machine. 12. If there is any slack in the harness pull it down [B].
  • Page 197 LCIT RT4040 (D3D6) 13. Push the LCIT [A] onto the joint pins on the side of the main machine. 14. Connect the LCIT [B] to the main machine. 15. Set the flat-head shoulder screw [A] on the tip of a screwdriver, and then fasten in the hole behind panel [B] to lock the LCIT against the side of the main machine.
  • Page 198 2. Installation 16. Re-attach the right panel of the LCIT. This completes installation of the LCIT heater.

  • Page 199: 1/2"X14" Paper Size Tray Type 9002 (B474)

    8 1/2"x14" Paper Size Tray Type 9002 (B474) 8 1/2"x14" Paper Size Tray Type 9002 (B474) Accessory Check Check the accessories and their quantities against this list: Description Q"ty 1. Cover 2. B4/LG frame 3. Bottom plate extension 4. Rear bracket 5.

  • Page 200: Installation Procedure

    2. Installation Installation Procedure 1. If the LCT is connected to the machine, open the cover and remove the paper. 2. To lower the LCT tray, cover the near end sensor [A] with one hand, and then press the tray down button [B].
  • Page 201 8 1/2"x14" Paper Size Tray Type 9002 (B474) 7. Attach the front bracket [A] with the beveled corner down. • If the brackets are difficult to install, raise the bottom plate with your hand. 8. Attach the rear bracket [B] with the beveled corner down. 9.
  • Page 202 2. Installation • The kit is set for B4. If you need to change the paper size to LG, do the following steps. 12. Move the front side fence [A] to the LG position and fasten. 13. Move the rear side fence [B] to the LG position and fasten. 14.
  • Page 203 8 1/2"x14" Paper Size Tray Type 9002 (B474) 15. Attach the harness (not shown) to the back of the plate and secure the sensor connector wire. 16. Attach the LCT cover [A] provided with the kit. 17. Re-attach the right cover [B]. 18.

  • Page 204: Multi-Folding Unit Fd4000 (D615)

    2. Installation Multi-Folding Unit FD4000 (D615) Accessories Check the quantity and condition of the accessories in the box against the following illustration and list. Description Q'ty 1. Joint Bracket 2. Paper Guide – Long 3. Paper Guide – Short (D131/D132/D133) 4.

  • Page 205: Installation

    Multi-Folding Unit FD4000 (D615) Description Q'ty 11. Power Cord*1 12. Sponge Strip : In China, do not use the power cord provided with this unit. Contact your supervisor and use the power cord specified for use in China. Installation • The unit must be connected to a power source that is close to the unit and easily accessible. •...

  • Page 206: Paper Guide, Sponge Strips

    2. Installation 4. Remove all tape and packing material from inside. 5. Remove the tape from the bottom of the door [A]. 6. Pull out the folding unit [B] and remove the tapes. Paper Guide, Sponge Strips 1. Select the short paper guide [A] and attach it. 2.

  • Page 207: Ground Plate

    Multi-Folding Unit FD4000 (D615) Ground Plate 1. Attach the ground plate [A] to the lower right edge of the unit. Docking 1. Fasten the joint bracket [A] to the left side of the upstream unit.
  • Page 208 2. Installation 2. Open the front door [A]. 3. At the front right corner, remove the screw of the lock bar [B]. Keep this screw. 4. Pull out the lock bar. • If you are docking to the main machine, you must first remove the plastic cap at the I/F cable connection point.

  • Page 209: Power Cord

    Multi-Folding Unit FD4000 (D615) Power Cord 1. Insert the power cord socket [A] into the power connection point. • In China, do not use this power cord provided with this unit. Contact your supervisor and use the power cord specified for use in China. 2.

  • Page 210: Finishing The Installation

    2. Installation Finishing the Installation 1. Set the leveling shoes and adjust the height of the unit. 2. Load some B4 paper in the 2nd tray of the main machine, and make several copies. 3. Check paper skew and side-to-side registration and correct if necessary. Proof Tray Auxiliary Plate 1.
  • Page 211 Multi-Folding Unit FD4000 (D615) • The plate should be used when Z-folded paper (all sizes) is output to the proof tray. • If the plate is not used with Z-folded output, the pages could mix and overlap.

  • Page 212: Finisher Sr4080 (D610)

    2. Installation Finisher SR4080 (D610) Accessory Check Check the accessories and their quantities against this list: Description Q"ty 1. Cushion 2. Table Extension 3. Leveling Shoes 4. Rear Joint Bracket 5. Front Joint Bracket 6. Entrance Guide Plate 7. Grounding Plate 8.

  • Page 213: Installation

    Finisher SR4080 (D610) Installation • Turn the machine off and unplug the power cord. 1. Unpack the finisher and remove all tapes and shipping retainers from the exterior of the finisher.
  • Page 214 2. Installation 2. Open the front door and remove all visible tapes and shipping materials (cardboard strips, packing cushions, etc.
  • Page 215 Finisher SR4080 (D610) 3. Remove tape and cardboard from behind and on the stacker unit [A]. 4. Remove tape and shipping material [B] below the stacker unit. 5. Remove the three shipping brackets marked with wired red tags ( x6).
  • Page 216 2. Installation 6. Pull the stacker unit out as far as it will go, and then remove the tape and cardboard from behind the stacker unit [A]. 7. If the material [B] is difficult to remove from the front, on the right side of the finisher pull it down to remove it.
  • Page 217 Finisher SR4080 (D610) 9. On the left side of the main machine, use the long screws to attach the joint brackets [A],[B] ( (M4 x 14). 10. Remove the connector cover on the left side of the main machine.
  • Page 218 2. Installation 11. Skip this step if you are going to install the Cover Interposer Tray. (You will attach the ground plate later at another location during the Cover Interposer installation.) -or- If you are not going to install the Cover Interposer Tray, install the grounding plate [A] now ( x 2) (M3 x 6).
  • Page 219 Finisher SR4080 (D610) 13. Set the screws in the side of the tray, and then set the keyholes of the table extension [A] over the screws ( x 2) (M4 x 8). 14. With the extension slightly loose against the edge of the tray, align the end of the table extension with the edge of the finisher.
  • Page 220 2. Installation If you are not going to install the Cover Interposer Tray, attach the entrance guide plate [B]. 18. Attach the shift tray. 19. Open the front door of the finisher. 20. Push the finisher [A] close to the left side of the main machine [B]. 21.
  • Page 221 Finisher SR4080 (D610) 22. Align the finisher with the joint brackets on the left side of the main machine, and then push the finisher slowly against the main machine. 23. Make sure that the top right edge of the finisher is parallel to the top left edge of the main machine. 24.
  • Page 222 2. Installation 25. Close the front door. 26. Connect the finisher I/F cable to the main machine. 27. Set the leveling shoes under the feet and level the finisher.

  • Page 223: Auxiliary Trays

    Finisher SR4080 (D610) Auxiliary Trays 1. Set the shift auxiliary tray [A] on the shift tray when you expect folded paper from the Multi Folding unit to be output to the shift tray. 2. Set the proof auxiliary tray in the proof tray when you expect Z-folded paper from the Multi Folding unit to be output to the proof tray.
  • Page 224 2. Installation 3. Peel the tape from the tray holder [A]. 4. Attach the tray holder to the back of the finisher [B]. 5. Store the auxiliary trays in the holder if they are not needed.

  • Page 225: Punch Units (B531/A812)

    Punch Units (B531/A812) Punch Units (B531/A812) This procedure describes installation of these punch units in the Finisher SR4080.: • Punch Unit Type 1075 3/2 (B531) • Punch Unit Type 1075 EU 2/4 (B531) • Punch Unit Type 850 SC (A812) •...

  • Page 226: Installation

    2. Installation Installation • Switch the machine off and unplug the machine before starting the following procedure. 1. If the finisher is connected to the machine, disconnect it. 2. Open the front door and remove the rear cover. 3. Unpack the punch unit and remove the motor protector plate [A] and the cam lock plate [B]. 4.
  • Page 227 Punch Units (B531/A812) 5. Remove the inner cover [A]. 6. Behind the inner cover at [B] and [C], press the lock tab to the right to release the inner cover from the frame. 7. Remove the plastic knockouts [D]. 8. Remove the paper guide [A].
  • Page 228 2. Installation 9. Install the sensor arm [A]. • Make sure that the sensor arm swings freely on the step screw. 10. Attach the spring [B]. 11. At the rear, position the 2 mm spacer [A] and attach the punch unit [B].
  • Page 229 Punch Units (B531/A812) • At the hole just above the lock lever, use one of the screws from the paper guide removed above to fasten the remaining two spacers to the frame. • These extra spacers are used to adjust the horizontal position of the punch holes. 12.
  • Page 230 2. Installation 16. Connect the single end of the hopper full sensor connector cable [C] to the hopper full sensor on the arm, and then connect the other two connectors to HP Sensor 1 [D] and CN620 [E] of the punch PCB.
  • Page 231 Punch Units (B531/A812) 18. Re-attach the inner cover and rear cover. 19. Close the front door and re-connect the finisher to the machine.

  • Page 232: Output Jogger Unit Type 9002B (B513)

    2. Installation Output Jogger Unit Type 9002B (B513) Accessory Check Check the accessories and their quantities against this list: Description Q’ty 1. Jogger Unit B513 2. Tapping Screws - M3 x 6 3. Installation Procedure Installation Procedure • This jogger unit for the Finisher SR4080 only. 1.
  • Page 233 Output Jogger Unit Type 9002B (B513) 3. Remove the cover plate [A] from the jogger unit. Keep these screws. 4. With the jogger unit harness and connector on the left, hook the frame of the jogger unit [A] into the holes on the left and right side of the finisher frame.
  • Page 234 2. Installation 7. Re-attach the jogger unit cover to its frame with the screws removed in Step 3.

  • Page 235: Cover Interposer Tray Ci4030 (D3D7)

    Cover Interposer Tray CI4030 (D3D7) Cover Interposer Tray CI4030 (D3D7) This Cover Interposer Tray is designed to be installed and used with Finisher SR4070. Accessories Check the quantity and condition of the accessories in the box against the following list. Description Q’ty 1.

  • Page 236: Installation

    2. Installation Installation Finisher SR4080 Already Installed? Do these procedures if the finisher is already installed on the main machine. 1. Turn the main machine off, and then disconnect it from the power source. 2. Unplug the finisher I/F cable at the rear right corner of the main machine [A].
  • Page 237 Cover Interposer Tray CI4030 (D3D7) 3. Open the finisher door. 4. Remove screw [1], and then pull out the lock bar [2]. 5. Pull the finisher away from the side of the main machine.
  • Page 238 2. Installation 6. Remove the paper entrance guide from the right side of the finisher. 7. Set the paper entrance guide aside. You will install it at another location later. 8. Remove the sponge strip from the top right edge of the finisher, and then attach it to the top left edge of the main machine.
  • Page 239 Cover Interposer Tray CI4030 (D3D7) 9. Remove the ground plate from the bottom right edge of the finisher [A], and keep the screws. 10. Set the ground plate and screws aside. You will install them at another location later.

  • Page 240: Remove Tapes And Retainers

    2. Installation Remove Tapes and Retainers 1. Remove all tapes and retainers from the exterior of the tray [A]. 2. Remove tape and cardboard from the collar of connector [B]. 3. Open the cover. 4. Remove all shipping material from inside. 5.

  • Page 241: Prepare The Finisher

    Cover Interposer Tray CI4030 (D3D7) Prepare the Finisher 1. On top of the finisher, remove the cover of the relay connector. 2. Remove the connector bracket.
  • Page 242 2. Installation 3. Attach the shoulder screws to the frame on the right side of the finisher. 4. Open the finisher door [A]. 5. Set the bottom plate [B].
  • Page 243 Cover Interposer Tray CI4030 (D3D7) 6. Attach the bottom plate at the front [A] and rear [B]. 7. Attach the ground plate (a finisher accessory) to the right edge of the bottom plate.
  • Page 244 2. Installation 8. Set two screws in the holes provided on the bottom half of the finisher front door [A]. Do not tighten these screws yet. 9. Set the keyholes of the hinges [B] on the bottom extension over the set screws, and then slide the extension down.

  • Page 245: Install Tray

    Cover Interposer Tray CI4030 (D3D7) • Tighten the screws. 14. Set two screws in the holes provided on the rear metal frame [A]. Do not tighten these screws yet. 15. Set the keyholes of the hinges [B] on the rear extension over the set screws, and then slide the extension down.
  • Page 246 2. Installation 1. Pick up the cover interposer tray, align the keyholes with the shoulder screws, and then slide the cover interposer down onto the screws. 2. Check under the finisher and confirm that the shoulder screws [A] are engaged correctly with the cutouts.

  • Page 247: Attach Corner Plates And Gaskets

    Cover Interposer Tray CI4030 (D3D7) Attach Corner Plates and Gaskets 1. At the right rear corner of the finisher, temporarily attach two screws with about two turns. 2. The holes are not visible because they are covered with tape. Just punch the screws through the holes.
  • Page 248 2. Installation 7. On the left side of the main machine, attach the joint brackets at the rear [A] and front [B]. (If the finisher was installed previously, the brackets are already attached.) 8. Remove the tape from both gasket seals. (These are Cover Interposer Tray accessories.)

  • Page 249: Attach Sponge Strips

    Cover Interposer Tray CI4030 (D3D7) 9. Attach one gasket on the rear joint bracket [A] and one gasket on the front joint bracket [B]. Attach Sponge Strips 1. Raise the cover [A] of the Cover Interposer Tray on top of the finisher. 2.

  • Page 250: Re-Attach Paper Entrance Guide

    2. Installation Re-attach Paper Entrance Guide 1. Discard the machine screws you removed with the paper entrance guide. 2. Replace them with the small tapping screws provided with the interposer tray. 3. Attach the paper entrance guide at the front right corner of the finisher [A]. 4.

  • Page 251: Dock The Finisher

    Cover Interposer Tray CI4030 (D3D7) Dock the Finisher 1. With the finisher door open, push the finisher against the side of the main machine [A]. 2. Push the lock bar [B] in completely, and then fasten it with the screw. 3.

  • Page 252: Finishers Sr4120/Sr4130 (D3Cg/D3Ch)

    2. Installation Finishers SR4120/SR4130 (D3CG/D3CH) Accessory Check Check the quantity and condition of the accessories against the following list. Q’ty Description SR4120 SR4130 Lower Output Tray Shift Auxiliary Tray Proof Auxiliary Tray Sponge Strip Docking Bracket Upper Output Tray Screws M3 x 6 Tapping Screws Screws M4 x 20 Screws M3 x 8...

  • Page 253: Installation Procedure

    Finishers SR4120/SR4130 (D3CG/D3CH) Q’ty Description SR4120 SR4130 Cushion Installation Procedure • Always switch the machine off and unplug the machine before doing the following procedure. Tapes and Retainers 1. Unpack the finisher and remove all tapes and packing materials from the finisher. 2.
  • Page 254 2. Installation 3. Remove the upper bracket with the red tag attached [A]. 4. Pull out the jogger unit, and then remove all remaining tapes and retainers.

  • Page 255: Preparing The Finisher

    Finishers SR4120/SR4130 (D3CG/D3CH) 5. Remove the lower bracket with the red tag attached [A]. Preparing the Finisher 1. Install the paper entrance guide [A] on the right side of the finisher.
  • Page 256 2. Installation 2. Do not attach the right upper cover if you are going to install Cover Interposer Tray CI4040 (DC3N). -or- Set the tabs of the right upper cover [A] at the right rear corner of the finisher, and then attach the cover at the front [B].

  • Page 257: Preparing The Main Machine

    Finishers SR4120/SR4130 (D3CG/D3CH) 4. Peel the tape from the large sponge strip. 5. Attach the strip to the right top edge of the finisher so it is 0 to 1 mm from the top edge. Preparing the Main Machine 1. Use the long screws to loosely attach the rear end [A] and front end [B] of the joint bracket to the left side of the main machine.
  • Page 258 2. Installation 2. With the joint bracket [A] floating freely on the loose screws, move the bracket to position screw [B] so it is centered exactly below the long line on the scale, and then tighten the four screws. 3. Peel the tape from coupling seal, and then attach it to the left side of the main machine between the exit rollers.

  • Page 259: Docking The Finisher

    Finishers SR4120/SR4130 (D3CG/D3CH) 5. Push the finisher close to the left side of the main machine. Docking the Finisher 1. Disconnect the lock bar by removing the screw [1], and then pull the lock bar [2] out until it stops.
  • Page 260 2. Installation 2. Push the finisher [A] against the side of the main machine. 3. Confirm that the gap between finisher and main machine is tight and perfectly even. 4. Firmly, push the lock bar [1] in until it stops, and then fasten screw [2].
  • Page 261 Finishers SR4120/SR4130 (D3CG/D3CH) 5. Connect the finisher connector to the machine. 6. Close the front door of the finisher. 7. Set the upper output tray [A], and then attach screw [B] under the tray.
  • Page 262 2. Installation 8. If you are installing Booklet Finisher CI4040, raise feeler arm [A], and then set the back edge of the tray [B] into the slots. (No screws.) 9. Install the hopper.

  • Page 263: Checking The Installation

    Finishers SR4120/SR4130 (D3CG/D3CH) 10. If the floor is uneven, you may want to use the four accessory shoes to level the machine with the four bolts and locknuts under the finisher. Checking the Installation 1. Turn on the main machine. 2.

  • Page 264: Auxiliary Trays

    2. Installation 4. If side-to-side registration is still shifting to either the rear of front of the machine, correct it. page 1498 5. Print out some sheets with center-folding and make sure that the sheets are folded evenly into equal halves.

  • Page 265: Using Auxiliary Trays

    Finishers SR4120/SR4130 (D3CG/D3CH) 3. Set the trays in the holder. Using Auxiliary Trays The trailing edges of excessively curled or Z-folded paper can activate the tray full sensors before the tray is actually full. Once this occurs and the "Exit Tray Full" message appears, the job stops and cannot continue until some sheets are removed from the tray which is only partially full.
  • Page 266 2. Installation Proof Support Tray (No. 1) Set auxiliary Tray 1 on the proof tray when using thin or soft paper that may not exit completely and interfere with the tray full sensor. Proof Auxiliary Tray (No. 2) Z-folded paper or paper with curled edges can interfere with the tray full sensor by signaling tray full before the tray is actually full.
  • Page 267 Finishers SR4120/SR4130 (D3CG/D3CH) Shift Auxiliary Tray (No. 3) Set auxiliary Tray 3 only when the Multi-Folding Unit is installed, especially when working with Z-folded paper. 1. The pegs [A] on the bottom of this tray fit into the holes on the shift tray [B]. 2.
  • Page 268 2. Installation...

  • Page 269: Punch Units (D706)

    Punch Units (D706) Punch Units (D706) These instructions describe installation of the following punch units for the Finisher SR4060/SR4070: • Punch Unit PU3060 SC (D706) • Punch Unit PU3060 2/4 EU (D706) • Punch Unit PU3060 NA 3/2 (D706) • These punch units can be installed and used with the Finishers SR4120 and SR4130 only. Accessory Check Check the quantity and condition of the accessories against the following list.

  • Page 270: Installation Procedure

    2. Installation Installation Procedure • Always switch the machine off and unplug the machine before doing the following procedure. 1. If the finisher is installed, disconnect it and pull it out of the line. 2. Remove the rear upper cover [A] of the finisher. 3.
  • Page 271 Punch Units (D706) 4. Open the front door [A], and then remove the punch hopper bracket [B]. 5. Pull out the stapling unit [A]. (Booklet Finisher only) 6. Remove the inner upper cover [A] from the Front of the finisher.
  • Page 272 2. Installation • Disconnect the harness from the back side of the inner upper cover when you remove the inner upper cover. 7. Remove screw [A] of the transport guide plate from the rear of the finisher.
  • Page 273 Punch Units (D706) 8. Remove the transport guide plate [A]. 9. Install the punch unit slide stay [A] from the rear of the finisher. 10. Fasten the punch unit slide stay at the front [A]...
  • Page 274 2. Installation 11. Fasten the punch unit slide stay at the rear [A] 12. Insert the paper chad guide [A] into the finisher as shown below. 13. First, hook the chad guide to the front [A]...
  • Page 275 Punch Units (D706) 14. Second, hook the chad guide to the rear [A] 15. At the rear, fasten the paper chad guide.
  • Page 276 2. Installation • When fastening the paper chad guide with the snap ring, make sure the Front of the paper chad guide is hooked onto the small-diameter slot [A]. 16. Insert the hopper bracket [A] into the finisher as shown below.
  • Page 277 Punch Units (D706) 17. Hook the hopper bracket onto the frame [A] [B] of the finisher.
  • Page 278 2. Installation • Make sure the hooks [A] and [B] of the hopper bracket are also hooked onto the finisher.
  • Page 279 Punch Units (D706) 18. Fasten the hopper bracket [A].
  • Page 280 2. Installation 19. Route the harness of the hopper bracket [A] inside the finisher as shown. 20. Route the harness of the hopper bracket to the rear of the finisher. 21. Insert the registration guide plate [A] from the rear of the finisher. •...
  • Page 281 Punch Units (D706) 22. Fasten the registration guide plate. Front Rear...
  • Page 282 2. Installation 23. Insert the registration sensor bracket [A] from the rear of the finisher. • Hook [A] of the registration sensor bracket into the slotted holes of the finisher. 24. Fasten the registration sensor bracket.
  • Page 283 Punch Units (D706) 25. Insert the punch unit [A] from the rear of the finisher. • Make sure the shaft [A] on the finisher is inserted into the punch unit [B].
  • Page 284 2. Installation • When inserting the punch unit, make sure the bracket [A] of the punch unit is in the right position as shown below. 26. Fasten the punch unit.
  • Page 285 Punch Units (D706) • Make sure the bracket of the punch unit fits the embossed parts [A] on the finisher. 27. Install the stepper motor bracket [A] from the rear of the finisher.
  • Page 286 2. Installation 28. Insert the hole [A] in the stepper motor bracket over the shaft [B] on the rear of the finisher. 29. Make sure the rack [A] of the punch unit is engaging with the pinion [B] of the stepper motor bracket when you insert the stepper motor bracket.
  • Page 287 Punch Units (D706) 30. Fasten the stepper motor bracket. 31. Connect the harness [A] of the registration sensor bracket to the harness [B] from the hopper bracket.
  • Page 288 2. Installation 32. Connect the harness [A] of the registration sensor bracket to the harness [B] from the punch unit. 33. Connect the harness connector cable provided with the punch unit to the main board [A] of the finisher.
  • Page 289 Punch Units (D706) • The end that is split into two connectors must be connected to the main board. 34. Route the harness connector cable as shown below. • Route the harness inside the I/F bracket [A] as shown below.
  • Page 290 2. Installation 35. Connect the harness connector cable to the PCB [A] on the punch unit. 36. Connect the harness [A] of the stepper motor bracket to the PCB [B] in the punch unit. 37. Connect the harness [A] of the registration sensor bracket to the PCB [B] in the punch unit. 38.
  • Page 291 Punch Units (D706) 39. When you clamp the harness in clamp [A], clamp the harness between the two binds [B]. 40. Route the harness [A] of the punch unit over the PCB as shown below. 41. Slide the punch waste hopper [A] into the finisher from the rear.
  • Page 292 2. Installation 42. Pull back the stapling unit. 43. Re-attach the covers, and then re-install the finisher on the main machine. 44. Connect the finisher connector to the main machine. 45. Turn on the main power switch of the machine. 46.

  • Page 293: Output Jogger Unit Type M25 (D3Cj)

    Output Jogger Unit Type M25 (D3CJ) Output Jogger Unit Type M25 (D3CJ) • This jogger unit is installed and used with the Finishers SR4120/SR4130 only Accessories Check the quantity and condition of the accessories against the following list. Description Jogger Unit Cover Jogger Unit Rear End Cover Front End Cover...

  • Page 294: Installation

    2. Installation Installation • Always switch the machine off and unplug the machine before doing the following procedure. 1. Disconnect the finisher from the main frame. 2. Remove the rear cover. 3. Remove the shift tray.
  • Page 295 Output Jogger Unit Type M25 (D3CJ) 4. Push the paper guides to the center. 5. Remove the rear paper guide cover. 6. Remove the front paper guide cover.
  • Page 296 2. Installation 7. Disconnect the main paper guide cover. 8. Carefully, separate the front tabs at [A], and then remove the main paper guide cover [B]. 9. Disconnect the cover installation bracket.
  • Page 297 Output Jogger Unit Type M25 (D3CJ) 10. Slowly, disconnect the bracket from the rail above, and then remove it. 11. At the rear [A], set one shoulder screw. 12. At the front [A], set the other shoulder screw.
  • Page 298 2. Installation 13. Spread the paper guides to the maximum width. 14. Move the jogger arms on the jogger unit to the center. 15. Hold the jogger unit so the hooks [A] on both ends of the unit are in line with the installed shoulder screws [B].
  • Page 299 Output Jogger Unit Type M25 (D3CJ) 17. Confirm that the rear bracket [A] is on the shoulder screw. 18. Confirm that the rear motor [B] is up under the tray. 19. Confirm that the front bracket [A] is on the shoulder screw. 20.
  • Page 300 2. Installation 21. Fasten the jogger unit at the rear [A] and front [B]. 22. Connect the jogger unit at the rear. 23. Peel the back off the two accessory cushions. 24. Attach the cushions to the front [A] and rear [B] of the lower arms of the output tray.
  • Page 301 Output Jogger Unit Type M25 (D3CJ) 25. Set the front end cover [A]. Do not attach the screw yet. 26. Set the rear end cover [A], and then fasten it [B].
  • Page 302 2. Installation 27. Look at the jogger cover. Note the tabs and slots on the rear end [A], center arm covers [B], and front end [C]. 28. Slowly, set the jogger cover [A] on the jogger unit. 29. At the rear [A] confirm that the tab inserts correctly. 30.
  • Page 303 Output Jogger Unit Type M25 (D3CJ) 31. In the center under the jogger unit, make sure the rear arm cover [A] and front arm cover [B] fit over the edge of the plate as shown. 32. After making sure that all tabs are set correctly, fasten the cover to the jogger unit. 33.
  • Page 304 2. Installation 34. Check the center of the shift tray. If the jogger arms are touching the surface of the shift tray as shown, this will cause a jam when the machine is turned on because the arms will move and hit the tray. 35.
  • Page 305 Output Jogger Unit Type M25 (D3CJ)

  • Page 306: Cover Interposer Tray Ci4040 (Dc3N)

    2. Installation Cover Interposer Tray CI4040 (DC3N) Accessories • This Cover Interposer Tray is designed for use with the Finisher SR4120 and Booklet Finisher SR4130 only. Check the accessories and their quantities against this list. Description Q'ty Front Door Top Extension Front Door Bottom Extension Rear Cover Extension Tray Mounting Bracket: Rear...

  • Page 307: Installation

    Cover Interposer Tray CI4040 (DC3N) Description Q'ty Screws (Silver) M3x6 Shoulder Screws (Blue) Installation Finisher Already Installed? If the finisher is installed, it must be separated from the main machine. 1. At the left rear corner of the machine [A], disconnect the finisher cable.
  • Page 308 2. Installation 2. Open the finisher door. 3. Remove screw [A] from the lock bar. Keep this screw. 4. Pull out lock bar [B] completely. 5. Pull the finisher away from the side of the machine.

  • Page 309: Prepare The Finisher

    Cover Interposer Tray CI4040 (DC3N) Prepare the Finisher 1. Remove the paper guide on the right side of the finisher. 2. If the finisher is the Booklet Finisher SR4130, remove the upper right plate [A]. (The Finisher SR4120 does not have this plate.)

  • Page 310: Shipping Tapes And Retainers

    2. Installation 3. Remove the sponge strip [A] from the upper right edge of the finisher. Shipping Tapes and Retainers 1. Remove tape from the top [A] of the tray. 2. Under the tray, remove the tape and cardboard on connector [B].

  • Page 311: Prepare The Main Machine

    Cover Interposer Tray CI4040 (DC3N) 3. Open the tray and remove all tape and pieces of cardboard. Prepare the Main Machine 1. On the left side of the main machine, unfasten rear end [A] and front end [B] of the joint bracket. 2.

  • Page 312: Cover Interposer Tray

    2. Installation Cover Interposer Tray 1. On top of the finisher, remove the connector cover [A]. 2. Remove metal cover [B]. 3. On the right rear inside panel of the finisher [A], fasten one shoulder screw.
  • Page 313 Cover Interposer Tray CI4040 (DC3N) 4. On the right front post of the finisher [A], fasten the other shoulder screw.
  • Page 314 2. Installation 5. To avoid damaging the guides on the right side of the unit, elevate the unit with some blocks, boxes, etc. so it is not flat on the floor. 6. Select the rear tray mounting bracket [A], and then locate its screw holes between the keyholes on the rear frame.
  • Page 315 Cover Interposer Tray CI4040 (DC3N) 7. Align the holes, and then fasten the tray mounting bracket to the frame. 8. Fasten the other mounting bracket to the front frame at [A] and [B].
  • Page 316 2. Installation 9. On the right side of the finisher, hold the tray unit over the finisher, and then align the hooks of the mounting brackets with the installed shoulder screws in the finisher. 10. Slowly, lower the tray unit hooks onto the shoulder screws inside the finisher. 11.

  • Page 317: Extensions

    Cover Interposer Tray CI4040 (DC3N) 13. Raise Q2. 14. Fasten one screw to fasten the tray to the frame at the rear. Extensions 1. Set two screws in the bottom half of the finisher front door [A]. 2. Do not tighten these screws [B].
  • Page 318 2. Installation 3. Set two screws in the top half of the finisher front door [A]. 4. Do not tighten these screws [B].
  • Page 319 Cover Interposer Tray CI4040 (DC3N) 5. Select the front door bottom extension. 6. Set the keyholes of the hinges [1] over the heads of the screws, and then slide the extension [2] down so the heads of the screws slide into the cutouts. 7.
  • Page 320 2. Installation 8. Select the front door top extension. 9. Set the keyholes of the hinges [1] over the heads of the screws, and then slide the extension [2] down so the heads of the screws slide into the cutouts.
  • Page 321 Cover Interposer Tray CI4040 (DC3N) 10. Check the top of the door and extension. • If the top the door and extension are not even [A], slide the extension up slightly [B]. • Tighten the screws.
  • Page 322 2. Installation 11. Attach the rear cover extension [A]. 12. Remove ground plate [A] from the bottom right edge of the finisher.
  • Page 323 Cover Interposer Tray CI4040 (DC3N) 13. Set the tab [1] and boss [2] of the ground plate extension on the bottom edge, and then fasten it with the screws. 14. Hook the ground plate to the right edge of the extension.
  • Page 324 2. Installation 15. Fasten the ground plate to the extension. 16. At the right front corner of the finisher [A], peel off the tape. 17. Set one screw [B]. Do not tighten it. 18. Select the right front corner plate (the smaller plate). 19.

  • Page 325: Sponge Strip

    Cover Interposer Tray CI4040 (DC3N) 22. Set two screws [B]. Do not tighten them. 23. When you attach the plate [C], lower the cutouts under the plate over the set screws. 24. Use a long screwdriver inserted through the cutouts under the plate [A] to tighten the screws and fasten the plate.

  • Page 326: Main Machine

    2. Installation 3. Attach the sponge to the bare plate. 4. Raise and lower the tray a few times to make sure that the strip is not sticking to the tray. Main Machine 1. On the left side of the main machine, attach the front joint bracket (marked "R") on the right side of the paper exit [A].
  • Page 327 Cover Interposer Tray CI4040 (DC3N) Attach gasket [A] to the front joint bracket. 3. Attach the rear joint bracket (marked "L") on the left side of the paper exit [A], and then attach the other gasket [B] to this bracket.

  • Page 328: Docking The Finisher

    2. Installation Docking the Finisher 1. Push the finisher close to the left side of the main machine. 2. Confirm that the lock bar is pulled out completely. 3. Push in the lock bar, and then fasten it with its screw.
  • Page 329 Cover Interposer Tray CI4040 (DC3N) • After docking the finisher, lower and raise guide Q2 to confirm that it opens and closes smoothly. • If it does not operate smoothly, make sure that the right side of the finisher is straight against the left side of the machine (or upstream unit).

  • Page 330: Finish The Installation

    2. Installation Finish the Installation 1. Plug in the machine and switch the machine on. 2. Enter the [System Settings]. 3. Select Cover Sheet Tray > Front Cover Sheet Tray > Back Cover Sheet Tray > Tray Paper Settings > Designation Sheet 2 Tray.

  • Page 331: Mailbox Cs4010 (D708)

    Mailbox CS4010 (D708) Mailbox CS4010 (D708) • The Mail Box can be installed on the SR4120/SR4130 only. The Mail Box cannot be installed on the SR4080. • The Mail Box and Cover Interposer tray cannot be installed together. (Only one will fit on top of the finisher.) Accessories Check the accessories and their quantities against this list.

  • Page 332: Installation

    2. Installation Installation • Turn the machine off and disconnect the machine power cord before you start this procedure. 1. Remove the filament tape [A]. • Move the mailbox carefully. The soft corner leaf [B] can be damaged easily. 2. At the rear left corner of the main machine, disconnect the finisher cable [A].
  • Page 333 Mailbox CS4010 (D708) 3. Open the front door of the finisher. 4. Remove lock screw [A]. Keep this screw. 5. Pull out lock bar [B] until it stops. 6. Pull the finisher away from the machine.
  • Page 334 2. Installation • If the Cover Interposer Tray is installed on the Finisher, it must be removed. Do this now. 7. Remove top cover [A] of the finisher.
  • Page 335 Mailbox CS4010 (D708) 8. Open the finisher door, and make sure that the lock bar is pulled out completely. 9. With the finisher door open, slowly, push the finisher against the left side of the machine. 10. Push the lock lever [A] into the finisher, and then fasten it with the screw [B]. 11.
  • Page 336 2. Installation 12. Attach guide plate [A] to the top of the finisher. 13. Attach the mailbox [A] to the top of the finisher. 14. Attach the 9 trays [B] to the mailbox. 15. Give the decals [C] to the customer. The operator will fill out the decals and attach them at the desired locations.
  • Page 337 Mailbox CS4010 (D708) 16. Turn the machine on. 17. Check the finisher operation.

  • Page 338: Copy Tray Type 9002 (B756)

    2. Installation Copy Tray Type 9002 (B756) Accessories Check the accessories and their quantities against the following list. Description Q’ty Copy Tray Actuator Arm and Bracket (not used) Tapping Screw (not used) Large Cap Small Cap Paper Height Sensor (Black Connector) Paper Height Sensor (White Connector) Not Used...

  • Page 339: Installation

    Copy Tray Type 9002 (B756) Installation • To avoid the hazard of electrical shock, before doing this procedure turn the machine off and unplug the machine from the power source. 1. Remove the left upper cover [A]. 2. Select the paper height sensor with the black connector. (The sensor with the white connector is not used for this machine.) 3.
  • Page 340 2. Installation 6. Reattach the left upper cover to the machine. 7. Attach the tray [A]. 8. Insert the small caps into the small holes. 9. Fasten the square cap as shown.

  • Page 341: Tab Sheet Holder Type 9002 (B499)

    Tab Sheet Holder Type 9002 (B499) Tab Sheet Holder Type 9002 (B499) The tab sheet holder can installed in trays 2 and 3, and allows the user to load tab stock. Accessories Check the quantity and condition of the accessories in the box against the following list. Description Q'ty Tab Sheet Holder...
  • Page 342 2. Installation 2. Check that the paper tray is not being used, and then pull the tray carefully out until it stops. 3. Install the tab sheet holder on the end fence of the paper tray. 4. When the tab sheet holder is installed correctly, you can hear a clicking noise. [A]: End fence [B]: Tab sheet holder...
  • Page 343 Tab Sheet Holder Type 9002 (B499) 5. Load tab stock in the paper tray so the side with the tab faces the tab sheet holder. 6. Adjust the end fence position so that the tab sheet holder will fit the tab stock. 7.

  • Page 344: Nfc Card Reader Type M19 (D3Bs)

    2. Installation NFC Card Reader Type M19 (D3BS) Accessories Check the quantity and condition of the accessories in the box against the following list and diagram. Description Q'ty Corner Cover (Not used) Reader Bracket Reader Cover Reader Sponge Cushions Ferrite Core (Black) Interface Cable...

  • Page 345: Installation

    NFC Card Reader Type M19 (D3BS) Installation 1. Turn the machine off. 2. Disconnect the machine from its power source. 3. Open the ADF. 4. Cover the exposure glass. 5. Disconnect the front edge cover of the scanner unit. 6. Remove the front edge cover. 7.
  • Page 346 2. Installation 8. Raise the operation panel [A] and then lay it face down on the exposure glass. 9. On the right, disconnect the blank cover. 10. Turn the operation panel face up. 11. Remove the cover so you can see the panel bracket below.
  • Page 347 NFC Card Reader Type M19 (D3BS) 12. The reader bracket has two large tabs under it. 13. Set these tabs into the holes in the panel bracket, and then slide the reader bracket toward the rear to lock the reader bracket in place. 14.
  • Page 348 2. Installation • Attach the ferrite core to either end of the interface cable. The connectors are identical. 15. Lift the operation panel and lay it face down. 16. Locate the connection point for the interface cable. 17. Connect the free end (no ferrite core) of the interface cable to the PCB.
  • Page 349 NFC Card Reader Type M19 (D3BS) 18. Set the cable in the notch of the frame [A]. 19. Lift the operation panel and turn it face up. 20. Raise the end of the cable with the ferrite core through the hole.
  • Page 350 2. Installation 21. Peel the tape from each side of the sponge cushions, and attach the cushions to the frame bracket. 22. Connect the card reader and the cable.
  • Page 351 NFC Card Reader Type M19 (D3BS) 23. Set the card reader on the sponge cushions attached to the reader bracket. 24. Hold the card reader cover with both tabs down.
  • Page 352 2. Installation 25. Set both tabs at the front edge of the reader bracket [A], and then lower the rear edge. 26. Press down until the rear edge [B] snaps into place. 27. This completes the installation. Re-attach the operation panel.

  • Page 353: Card Reader Bracket Type 3352 (D593)

    Card Reader Bracket Type 3352 (D593) Card Reader Bracket Type 3352 (D593) Accessories Check the accessories and their quantities against this list. Description Table Top Table Frame Table Bottom Screw M4x35 Screw M3x6 Screw M3x8...

  • Page 354: Installation

    2. Installation Installation 1. At the right rear corner, remove the I/F harness connector cover. 2. On the right side of the machine, lower bypass tray [1], remove screw [2], and then remove right upper cover [3]. 3. Lay the cover down with the inner surface of the rear upper corner facing up. 4.
  • Page 355 Card Reader Bracket Type 3352 (D593) 5. Clean the holes so they are smooth. 6. Reattach the right upper cover to the machine ( x1). 7. Fasten the long accessory screws in the holes and leave about 2.5 cm (1”) of the screw heads protruding.
  • Page 356 2. Installation 8. Bring the flat side of the table frame to the side of the machine. 9. Align the knockout in the side of the frame with the harness connector port [1], and then hang the keyholes on the side of the frame over the heads of the screws [2] and [3]. 10.
  • Page 357 Card Reader Bracket Type 3352 (D593) 12. Set the hooks on the left edge of the table top [A] into the holes in the table frame, and then lower the top onto the frame. 13. Run the card reader I/F harness [B] through the center of the table. 14.
  • Page 358 2. Installation 15. Attach the table bottom under the table frame. 16. Fasten the front left corner of the table [A]. 17. Fasten the rear left corner of the table [B]. 18. Fasten the front right corner of the table [A].
  • Page 359 Card Reader Bracket Type 3352 (D593) 19. Fasten the rear right corner of the table [B]. 20. This completes installation of the card reader table.

  • Page 360: Optional Counter Interface Type M12 (B870)

    2. Installation Optional Counter Interface Type M12 (B870) Accessories Check the accessories and their quantities against this list. Description 1. PCB: MKB 2. Harness (MKB to IOB) Not Used 3. Harness (MB to MKB) Not Used 4. Screws M3x6 5. Standoffs 6.

  • Page 361: Installation

    Optional Counter Interface Type M12 (B870) Installation • Before doing this procedure, to prevent electrical shock always switch the machine off and then disconnect it from the power source. 1. Switch the machine off. 2. Disconnect the machine from the power source. 3.
  • Page 362 2. Installation 9. Attach the PCB [A] to the standoffs on the frame. 10. Connect harness [B] to the PCB.

  • Page 363: Copy Connector Type M25(D3D3)

    Copy Connector Type M25(D3D3) Copy Connector Type M25(D3D3) With this option you can connect two machines to perform simultaneous copying for the same job. Accessories Check the accessories and their quantities against this list: Description Q’ty 1. PCB D3D3 2. LAN Cable Installation •...
  • Page 364 2. Installation 2. Insert one of the boards in the slot. 3. Tighten the knob screws with your fingers. • To avoid damage to the board, never tighten these knob screws with a screwdriver. 4. In the same way, install the other board in the right slot of the other machine. 5.

  • Page 365: External Keyboard Bracket Type M3 (D3Dh)

    External Keyboard Bracket Type M3 (D3DH) External Keyboard Bracket Type M3 (D3DH) Accessories Description Q’ty Cover (for card reader) Cover (no card reader) Keyboard Holder Screws Installation The external keyboard can be installed with or without a card reader. Do the first procedure below to install only the keyboard.
  • Page 366 2. Installation 3. Open the ADF. 4. Remove the square cover on the right side of the operation panel. 5. Remove a USB port cover on the right edge of the operation panel. 6. Set and fasten the keyboard holder...
  • Page 367 External Keyboard Bracket Type M3 (D3DH) 7. Remove the tape from the holder. 8. Connect the USB cable to the right edge of the operation panel [A] and then set the keyboard [B] in the holder. 9. Attach the cover without the cut-out.

  • Page 368: External Keyboard With Card Reader

    2. Installation External Keyboard with Card Reader Do this procedure to install the external keyboard together with a card reader. 1. Turn the machine off. 2. Disconnect the machine from its power source. 3. Open the ADF. 4. Cover the exposure glass. 5.
  • Page 369 External Keyboard Bracket Type M3 (D3DH) 8. Remove a USB port cover on the right edge of the operation panel. 9. Raise the operation panel [A] and then lay it face down on the exposure glass. 10. Remove the left edge cover.
  • Page 370 2. Installation 11. Remove left upper cover [A] and rear upper cover [B]. 12. With the operation panel turned face down, disconnect the blank cover and remove it. 13. Turn the operation panel face up.
  • Page 371 External Keyboard Bracket Type M3 (D3DH) 14. Set the rear upper cover. 15. Pass the card reader cable through the cover cut-out, and then connect the cable to one of the USB ports. 16. Pass the cable over the left, rear corner [A], and then clamp it to the left side of the frame [B]. 17.
  • Page 372 2. Installation 20. Pass the cable behind the I/F cable and ground wire [A] 21. Set the cable on support [B]. 22. Pass the end of the cable through the cover [C]. 23. Turn the cover face up, set it, and then fasten left side [A] and right side [B].
  • Page 373 External Keyboard Bracket Type M3 (D3DH) 24. Set the keyboard holder [A] and then fasten it. 25. Set the tabs [B] on the bottom of the card reader bracket (provided with card reader accessories) into the holes on the keyboard holder, and then slide it to the left to lock it. 26.
  • Page 374 2. Installation 28. Connect the keyboard USB cable to the right edge of the operation panel [A] and then set the keyboard [B] in the holder. 29. Attach the cover with the cut-out for the card reader...
  • Page 375 External Keyboard Bracket Type M3 (D3DH)

  • Page 376: Internal Options

    2. Installation Internal Options List of Slots The internal options are the options that are available on I/F cards inserted into the controller board. • Tandem I/F Card. The left slot is used exclusively for the I/F card used to slave one machine to another.

  • Page 377: Inserting Cards

    Internal Options Name Item Ethernet Standard SD Card Slots Slot 1 Controller options on SD cards Slot 2 Service slot (firmware updates, etc.) Option (I/F Slot) File Format Converter Type M19 IEEE 1284 Interface Board Type M19 IEEE 802.11 a/g/n Interface Unit M19 Extended USB Board Type M19 USB Device Server Option Type M19 Tandem (I/F Slot)
  • Page 378 2. Installation 2. Insert the edge of the board into the groove at the top and bottom of the right side of the slot. 3. Slowly push the board into the slot until you feel it connect with the controller board. 4.

  • Page 379: Ieee 1284 Interface Board Type M19

    IEEE 1284 Interface Board Type M19 IEEE 1284 Interface Board Type M19 Accessories Description Q'ty IEEE 1284 Centronics Board Only one I/F slot (labeled "Option") is available for one of these options: • Centronics 1284 • IEEE 802.11a/g/n (Wireless LAN) •...
  • Page 380 2. Installation 3. Insert the board [A] into the slot. 4. Tighten the knob screws [B] with your fingers. • To avoid damage to the board, never tighten these knob screws with a screwdriver.

  • Page 381: Ieee 802.11 A/G/N Interface Unit M19

    IEEE 802.11 a/g/n Interface Unit M19 IEEE 802.11 a/g/n Interface Unit M19 Accessories Check the quantity and condition of the accessories in the box against the following list and diagram. Description Q'ty 1. IEEE802.11 a/g/n 2. Velcro Fasteners 3. Clamps Before You Begin Observe the following points when installing and using this unit: •...

  • Page 382: Installation

    2. Installation • Depending where you use this product, or the access point you select, restrictions may be imposed on the use of some channels. If wireless LAN communications are not possible, check the environment or access point. • You cannot use this option if you use Ethernet. Check the markings on the antenna brackets and the ferrite cores of the antenna cables.
  • Page 383 IEEE 802.11 a/g/n Interface Unit M19 • Never put your hand or a tool into the box when you remove the controller box or install an option. • To prevent damage to the circuits on the boards, always touch a metal surface to discharge static charge from your hands before you handle a board.
  • Page 384 2. Installation 7. Pull the antennas away from machine and make sure that they are not tangled. 8. Look at the markings on the antenna bracket. • ANT1. Antenna 1 transmits and receives. The ferrite core on the Antenna 1 cable is black. It must be installed at the top center of the rear cover [1].
  • Page 385 IEEE 802.11 a/g/n Interface Unit M19 10. Select Antenna 1, with the black ferrite core [A] on its cable, and then attach it to the center [B]. • The tips of the antennas should not be above the edge of the rear cover. •...
  • Page 386 2. Installation 11. Attach the other antenna [A] behind the right rear corner of the machine. • Like the other antenna, the tip of this antenna should be perfectly vertical and not above the rear edge of the cover. 12. Attach two clamps to the left of the controller box faceplate, set both harnesses in the clamps, and then close the clamps.
  • Page 387 IEEE 802.11 a/g/n Interface Unit M19 13. Attach two clamps to the rear cover as shown, set both harnesses in the clamps, and then close the clamps. 14. Keep the unused clamps, or you can attach additional clamps to the harnesses.

  • Page 388: User Tool Settings For Wireless Lan

    2. Installation 15. Turn on the main machine. 16. Confirm that the machine can recognize the unit: > >User Tools > Printer Features > List/Test Print > Configuration Page 17. If reception is poor, you may need to move the machine. User Tool Settings for Wireless LAN Do the procedure below to perform the initial interface settings for IEEE 802.11 a/g.

  • Page 389: Sp Mode And Up Mode Settings For Ieee 802.11 A/G Wireless Lan

    IEEE 802.11 a/g/n Interface Unit M19 • Range: 1-11 channels (default: 11) • In some countries, only the following channels are available: • The allowed range for the channel settings may vary for different countries. 8. WEP (Encryption) Setting. The WEP (Wired Equivalent Privacy) setting is designed to protect wireless data transmission.
  • Page 390 2. Installation SP No. Name Function WEP Key Used to confirm the current WEP key setting. WEP Mode Used to show the maximum length of the string that can be used for the WEP Key entry.

  • Page 391: File Format Converter Type M19

    File Format Converter Type M19 File Format Converter Type M19 Accessory Check Check the accessories and their quantities against this list: Description Q'ty File Format Converter (MLB: Media Link Board) Installation 1. Switch the machine off. 2. Remove the cover of the "Option Slot" on the right.
  • Page 392 2. Installation 3. Insert the board into the slot. 4. Tighten the knob screws with your fingers. • To avoid damage to the board, never tighten these knob screws with a screwdriver. 5. Switch the machine on. 6. Set SP5836-3 to "1" to enable the print backup feature. 7.
  • Page 393 File Format Converter Type M19 SP No. Setting SP No. Setting 5-836-2 5-836-85 5-836-3 5-836-86 5-836-72 5-836-91 8. Set the following SP codes according to the customer's needs. SP No. Setting Comment SP5-836-94 Selects JPEG2000 file format for documents copied from the document server to Palm2.

  • Page 394: Usb Device Server Option Type M19

    2. Installation USB Device Server Option Type M19 Accessories Items Q’ty Interface Board USB Cable Ferrite Core Bands (Not Used) • An Ethernet cable is not provided with this option.

  • Page 395: Interface Board

    USB Device Server Option Type M19 Interface Board • Take moment to see what is on the interface board faceplate before you install it because after installation it may be upside down. Item Description Switch Pressure switch used to reset to the factory settings. Ethernet port Used to connect the network Ethernet cable.
  • Page 396 2. Installation • When you install this option on the main machine for the first time, the interface board must be connected directly to your PC to set up the IP address and other network settings. 1. Turn off the main power of the machine, and unplug the power cord from the wall socket. 2.
  • Page 397 USB Device Server Option Type M19 • Tighten these knob screws with your fingers. • Never use a screwdriver to tighten these screws. • If a screw is tightened with too much pressure, this could damage the I/F board or the edged connectors between the I/F card and the controller board.
  • Page 398 2. Installation 8. Attach a ferrite core to each end of the network Ethernet cable so there is about 3 cm (1.2”) between the core and head of the connector. 9. Insert one end of the Ethernet cable into the Ethernet connector of the interface board.

  • Page 399: Ethernet Port Leds

    USB Device Server Option Type M19 10. Insert the other end of the Ethernet cable to a PC for the network setup. 11. Plug the power cord into the wall socket and turn on the main power of the machine. •...

  • Page 400: Notes For Energy Save Mode Setting

    2. Installation LED Color Indicates: Green and Yellow 1000BASE-T Green 10BASE-T Yellow 100BASE-TX Notes for Energy Save Mode Setting If the machine which has this option enters into the Energy Save Mode, you cannot print because this will cause a communication error. Follow the procedure below to disable the Energy Save Mode function.
  • Page 401 USB Device Server Option Type M19 • You cannot change the IP address for this option from the operation panel of the main machine. The setting must be done from a web browser on your PC. • The network setting of this option is initially assigned as follows: IP address: 192.168.100.100 / Subnet mask: 255.255.255.0 •...
  • Page 402 2. Installation 9. Set other items if required. 10. Press [Set] 11. Close the Web Browser. 12. Disconnect the Ethernet cable from the PC. 13. Connect the Ethernet cable to a network device (e.g. switching hub). 14. Set the IP address of this option in the printer driver which you use.

  • Page 403: Extended Usb Board Type M19

    Extended USB Board Type M19 Extended USB Board Type M19 Accessories Description Q'ty Extended USB Board M19 Only one I/F slot (labeled "Option") is available for one of these options: • Centronics 1284 • IEEE 802.11a/g/n (Wireless LAN) • File Format Converter •...
  • Page 404 2. Installation 3. Insert the board into the slot. 4. Tighten the knob screws with your fingers. • To avoid damage to the board, never tighten these knob screws with a screwdriver.

  • Page 405: Sd Card Options

    SD Card Options SD Card Options Overview Two SD card slots are provided on the controller box. • Slot 1. Slot 1 is where most SD cards with applications on them are inserted for either use or downloading. When merging (copying) applications from one SD card to another, Slot 1 holds the target SD card (the application is moved to this card from the SD card in Slot 2.) •...

  • Page 406: Inserting Sd Cards

    2. Installation • IPDS Unit Type M25 (D3D4) • OCR Unit Type M13 (D3AC) • PostScript3 Type M25 (D3D4-05) • SD Card for Fonts Type D (D641) • XPS Direct Print Option Type M25 (D3D4) • If the customer wants to use more than one application on SD cards, applications must be merged on the same SD card.

  • Page 407: Move Exec: Merging Applications

    SD Card Options 3. With its corner notch down and label facing the front of the machine, insert the SD card into Slot 2. 4. Push the SD card in until it clicks and locks in place. • Pushing in the SD Card also releases it for removal. •...
  • Page 408 2. Installation • Due to copyright restrictions, some applications may not allow you to copy the application to another SD card with Move Exec. • In this case, just use the SD with the restricted application as the target SD card for Move Exec. 1.

  • Page 409: Undo Exec: Unmerging Applications

    SD Card Options 7. Turn the main machine on. 8. Do SP5873-001. 9. Touch "Execute". 10. Follow the instructions on the display to complete the procedure. 11. Turn the machine off. 12. Remove the Source SD card from Slot 2. Leave the target SD card in Slot 1. 13.

  • Page 410: Storing Original Sd Cards

    2. Installation • The SD card in Slot 2 must be the original SD card of the application you want to move from Slot 1 to Slot 2. You cannot use any blank SD card in Slot 1. 4. Turn the main switch ON. 5.
  • Page 411 SD Card Options 4. Bend the ends of the cover toward you slightly to disengage the tabs on the ends, and then remove the front edge cover. 5. Locate the slots at the upper right corner of the operation panel display [A]. 6.

  • Page 412: Ocr Type M13

    2. Installation OCR Type M13 What is Searchable PDF? • Searchable PDF embeds the text information in the scanned document without processing the data on a computer. • If this option is installed: 1. You can search the text in the scanned document. 2.

  • Page 413: Installation

    OCR Type M13 Installation • Unplug the main machine power cord before you do the following procedure. 1. Remove the SD card slot cover. 2. Insert the OCR SD card in Slot 2 with its label facing the front of the machine. 3.
  • Page 414 2. Installation • If the machine returns the “Failed” alert, check if the SD card to determine if it has already been used. • Turn off the machine and then steps 1 to 5 again. 6. Cycle the machine off/on. 7.

  • Page 415: Restoration

    OCR Type M13 • The searchable PDF function can be switched on/off on the [OCR Settings] screen after installing the OCR unit. • If you want to use the searchable PDF function, select [On] for [OCR Settings]. (Default: [Off]) Restoration After installation of the OCR Unit: •...
  • Page 416 2. Installation • When you re-install the OCR Unit Type M2, do the same procedure as the original installation procedure.

  • Page 417: Postscript3 Unit Type M25

    PostScript3 Unit Type M25 PostScript3 Unit Type M25 Accessories Description Q'ty 1. PostScript3 Emulation SD Card 2. Decal • Only Slot 1 is available for applications on SD cards. If more than one application will be used, the applications must be merged onto one SD card with SP5873 -1. Installation 1.
  • Page 418 2. Installation 3. Set the SD card with it is label facing the front of the machine, and then push it in until it clicks. 4. Switch the machine on. 5. Print an SMC report to confirm that the machine recognizes the option. 6.
  • Page 419 PostScript3 Unit Type M25...

  • Page 420: Ipds Unit Type M25

    2. Installation IPDS Unit Type M25 Check the quantity and condition of the accessories in the box against the following list and diagram. Accessories Description Q'ty IPDS Emulation SD Card Decal Installation • Unplug the main machine power cord before you do the following procedure. 1.
  • Page 421 IPDS Unit Type M25 2. Insert the target SD card into Slot 1 [1] with its label facing the front of the machine. 3. Insert the IPDS SD card into Slot 2 [2] with its label facing the front of the machine. 4.

  • Page 422: Xps Direct Print Option Type M25 D3D4

    2. Installation XPS Direct Print Option Type M25 D3D4 Check the quantity and condition of the accessories in the box against the following list and diagram. Accessories Description Q'ty SD Card Installation 1. Remove SD card slot cover [A].
  • Page 423 XPS Direct Print Option Type M25 D3D4 2. Insert the XPS card in Slot 1. • If another card is in Slot 1, do Move Execute to move the content of the XPS card to the card in Slot 1. page 405 3.
  • Page 424 2. Installation 4. The card in Slot 1 must remain in Slot 1.

  • Page 425: Data Overwrite Security Unit Type M19 (D3Bs)

    Data Overwrite Security Unit Type M19 (D3BS) Data Overwrite Security Unit Type M19 (D3BS) Overview This option should be installed only for the customer who requires the CC certified Data Overwrite Security function. The function of this option is completely the same as the Data Overwrite Security in Security Functions, which is standard on this machine.

  • Page 426: Seal Check And Removal

    2. Installation If any of these settings is at a factory default value, tell the customer these settings must be changed before you do the installation procedure. 3. Make sure that “Admin. Authentication” is ON. [System Settings] > [Administrator Tools] > [Administrator Authentication Management] > [Admin. Authentication] If this setting is OFF, tell the customer this setting must be ON before you do the installation procedure.

  • Page 427: Installation Procedure

    Data Overwrite Security Unit Type M19 (D3BS) Installation Procedure 1. Turn the main power OFF. 2. Remove the SD card slot cover ( ×1) 3. Insert the SD card into SD Slot 1 with its label facing the front of the machine. 4.
  • Page 428 2. Installation 5. Do SP5-878-001 to install the application.

  • Page 429: After Installation Check

    After Installation Check After Installation Check Safety Check Check the following points after installing the machine, or after moving or transporting it to a new location. Consult with the operator before making or scheduling any changes. Determine which changes should be done by the client and those that should be done by the service technician. Check List The answer should be “Yes”...
  • Page 430 2. Installation Item Done by: Client Power source rated correctly for machine specifications, and initial display does not flicker after power on? Is machine grounded properly? Setup Location Machine located away from space heaters, heating ducts, humidifiers? Ambient temperature stable and not subject to wide range of low/ high temperatures which could cause condensation in the machine? Machine located away from direct sunlight and open windows (protected from dust, rain)?

  • Page 431: Security Setting

    Security Setting Security Setting Security Function Installation The machine contains two security functions: Data Overwrite Security and HDD Encryption. Both are built-into the firmware on the controller board. • If you are installing a new machine, and the user wants to use these security functions, you must log in as the System Administrator and activate Data Overwrite Security and HDD Encryption by selecting "Format All Data"...
  • Page 432 2. Installation 2. Press [System Settings]. 3. Press [Administrator Tools]. 4. Press [Next] three times. 5. Press [Auto Erase Memory Setting]. 6. Press [On]. 7. Select the method of overwriting. • If you select [NSA] or [DoD], proceed to step 10. •...

  • Page 433: Hdd Encryption

    Security Setting Icon 1 This icon is lit when there is temporary data to be overwritten, and blinks during overwriting. Icon 2 This icon is lit when there is no temporary data to be overwritten. HDD Encryption Before You Begin the Procedure: 1.
  • Page 434 2. Installation 1. Turn on the main power. 2. Log in as the machine administrator from the control panel. 3. Press [System Settings]. 4. Press [Administrator Tools]. 5. Press [Next] three times. 6. Press [Machine Data Encryption Settings]. 7. Press [Encrypt]. 8.

  • Page 435: Backing Up The Encryption Key

    Security Setting If you have selected [Print on Paper], press the [Start] key. Print out the machine's data encryption key. 10. Press [OK]. 11. Press [Exit]. 12. Press [Exit]. 13. Log out. 14. Turn off the main power, and then turn the main power back on. The machine will start to convert the data on the memory after you turn on the machine.

  • Page 436: Encryption Key Restoration

    2. Installation 2. Press [System Settings]. 3. Press [Administrator Tools]. 4. Press [Next] three times. 5. Press [Machine Data Encryption Settings]. 6. Press [Print Encryption Key]. 7. Select the backup method. If you have selected [Save to SD Card], load an SD card into the media slot on the side of the control panel and press [OK];...
  • Page 437 Security Setting 3. Create a folder in the “restore_key” folder and name it the same as machine’s serial number, “xxxxxxxxxxx” (11 digits). 4. Create a text file called "key_xxxxxxxxxxx.txt" and save it in the "xxxxxxxxxxx“ folder. Write the encryption key in the text file. /restore_key/xxxxxxxxxxx/key_xxxxxxxxxxx.txt •...
  • Page 438 2. Installation • Do not use quotation marks or blank spaces. • It is judged that a forced start has been selected when the content of "nvclear" is executed and the machine shifts to the alternate system (forced start). 4. Confirm that a message is displayed on the LCD telling to insert the SD card that contains the encryption key.

  • Page 439: Remote Settings

    @Remote Settings @Remote Settings • Prepare and check the following check points before you visit the customer site. For details, ask the @Remote key person. Check points before making @Remote settings 1. The setting of SP5816-201 in the mainframe must be "0". 2.
  • Page 440 2. Installation Value Meaning Solution/ Workaround Request number confirmation Processing… Please wait. executing Already registered Parameter error Dial-up authentication error Answer tone detection error Carrier detection error These errors occur only in the modems that Invalid setting value (modem) support @Remote. Low power supply current unplugged modem Busy line...
  • Page 441 @Remote Settings Value Meaning Solution/ Workaround Dial-up authentication error Answer tone detection error Carrier detection error These errors occur only in the modems that Invalid setting value (modem) support @Remote. Low power supply current unplugged modem Busy line 8. Exit the SP mode. SP5816-208 Error Codes: Caused by Operation Error, Incorrect Setting Code Meaning...
  • Page 442 2. Installation Code Meaning Solution/ Workaround The ID2 in the NVRAM does not match -12009 Check ID2 of the mainframe. the ID2 in the individual certification. -12010 The certification area is not initialized. Initialize the certification area. Error Caused by Response from GW URL Code Meaning Solution/ Workaround...

  • Page 443: User Instructions

    User Instructions User Instructions Operation Guidance for Users Function/Operation Instruction to provide Basic machine functions, • How to load the toner bottle operations • How to load paper and other consumables/supplies • How to turn the main power switch ON/OFF •...
  • Page 444 2. Installation Function/Operation Instruction to provide Scanner (when installed) • How to install printer drivers (using the recommended method) • How to connect to a PC and perform a test scan...

  • Page 445: Preventive Maintenance

    3. Preventive Maintenance PM Tables The amounts mentioned (K=1,000) as the PM interval indicate the number of prints or copies unless stated otherwise. These numbers are based on the PM counter. Symbol Key Letter Meaning As Necessary, or at scheduled maintenance Clean Emergency Maintenance Expected service life...

  • Page 446: Around The Drum

    3. Preventive Maintenance Item 300K Note Reflectors Optics cloth Scanner Guide Rails After cleaning with alcohol, lubricate with Launa Oil. (both sides) Toner Shield Glass Optics cloth Around the Drum Item 300K 450K Exp. Note Charge Corona Casing Damp cloth Charge Corona Grid 450K Blower brush...

  • Page 447: Drum Cleaning

    PM Tables Drum Cleaning Item 300K Exp. Note Cleaning Blade 500K Dry cloth Cleaning Brush Poor blade cleaning causes distorted images. Cleaning Entrance Seal Inspect for cracks, fissures. Dry cloth Cleaning Unit Casing Dry cloth Internal Dust Filter Blower brush Side Seals Dry cloth Toner Collection Bottle...

  • Page 448: Paper Feed: Main Paper Path

    3. Preventive Maintenance Item 300K Note Side Seals Blower brush, dry cloth Toner Bottle Gear Blower brush Toner Bottle Holder Dry cloth Toner Hopper Dry cloth Toner Trap Dry cloth Used Toner Separation Unit Remove front knob and rear gear of development unit and inspect the shaft. After 3000K inspect every 300K.

  • Page 449: Transfer Belt Unit

    PM Tables Item 300K 600K Note Paper End Sensors 1, 2, 3 Blower brush Paper Feed Guide Plate Dry cloth Paper Feed Sensors 1, 2, 3 Blower brush Pick-up Rollers 1, 2, 3 See Notes below this table. Separation Rollers Vertical Guide Plate Dry cloth Vertical Path Relay Sensor...

  • Page 450: Fusing Unit And Paper Exit

    3. Preventive Maintenance 300K 450K Exp. Note Transfer Roller Cleaning Blade 750K Dry cloth Always clean the transfer belt unit casing before replacing the discharge plate. Dirty backside printing and poor paper separation from the drum are signs that the transfer belt and transfer roller cleaning blade need replacement.

  • Page 451: Fusing Unit Paper Exit

    PM Tables Item 360K Exp. Note Thermistors x2* Inspect and clean with blower brush every 200K. Always replace cleaning web pressure roller and roller bearings together. Frequent fusing unit jams, excessive toner on prints, and pawl tracks on paper edges indicate the strippers should be replaced.

  • Page 452: Adf

    120K Note CIS exit roller Alcohol damp cloth, then water damp cloth CIS glass Wipe with clean cloth and Ricoh contact glass cleaner (A1939310). Driver rollers Alcohol damp cloth, then water damp cloth Exit roller Alcohol damp cloth, then water damp cloth...

  • Page 453: Optional Peripheral Devices

    PM Tables Pick-up roller, feed roller, and separation roller should always be replaced together as a set. Optional Peripheral Devices LCIT 4040 (D3A6-17, -27) 300K 450K 1000K Exp. Note Pick-up Roller 1000 Always replace these rollers as a set. The target service life of the Feed Roller 1000 feed, pick-up, and separation...

  • Page 454: Finisher Sr4080 (D610)

    3. Preventive Maintenance Note: The PM interval is for the number of sheets that have been fed. 120K 180K Exp. Note Feed Belt Pick-up Roller Replace as a set. Separation Roller Driver Rollers Damp clean cloth. Idle Rollers Damp clean cloth. Discharge Brush Damp clean cloth.

  • Page 455: Punch Unit Type Pu3060 (D706)

    PM Tables 1000 3000 300K 500K Exp. Note Roller Shafts Lubricate bushings with silicone oil, other bushings with Launa oil. Sensors Blower brush Corner Stapler 3000K Print an SMC report with SP5990. Replace the unit if the staple count is 500K. Booklet Stapler 1000K Print an SMC report with SP5990.

  • Page 456: Related Sp Codes

    3. Preventive Maintenance Part PM Visit Notes Fold rollers (1st, 2nd, 3rd) Alcohol, clean cloth Crease rollers (drive, idle roller) Related SP Codes This is a list of the PM related SP codes. SP7803 PM Counter Display Displays the PM count since the last PM. SP7804 PM Counter Reset Resets the PM count.

  • Page 457: Image Quality Tables

    Image Quality Tables Image Quality Tables Checking Image Quality Resolution Standard 1:1/Enlargement: 4.5 lines/mm or more Reduction: 4.5 x M or more mag. What You Need S-2-1 Chart Method Resolution measured after copying in Text Mode at AE5 notch with Normal Paper Even Density Standard...

  • Page 458: Magnification Errors

    3. Preventive Maintenance Magnification Errors Standards Main scan: <±0.5%, Sub scan: <±0.8% Magnification Main scan: <±1.0%, Sub scan: <±1.0% What You Need 150 mm scale Method 1. Set two scales on the exposure glass, and then copy them. 2. Wait at least 10 min. after the paper exits. 3.
  • Page 459 Image Quality Tables Method 1. Place three 150 mm scales on the exposure glass, and then copy them. 2. Wait at least 3 min. after the paper exits. 3. Use a scale to measure 100 mm against each scale image (x1, x2, x3) on the paper.

  • Page 460: Paper Transfer Quality Standards

    3. Preventive Maintenance Paper Transfer Quality Standards Registration Standard: Main Machine Simplex Engine Sub scan 0±0.5 mm Copy Sub scan 0±1.5 mm Duplex Engine Sub scan 0±0.5 mm Copy Sub scan 0±1.5 mm Standard: Main Machine + ADF Copy Paper (40 to 128 g/m Front Side Reverse Side Plotter...

  • Page 461: Skew

    Paper Transfer Quality Standards Method 1. Make a 1:1 copy of the S-2-1 chart with normal paper. 2. Use the scale to measure the registration marks at the leading edge. 3. The range is vertical registration A: 5 mm, and horizontal registration B: 4 mm for the front side.
  • Page 462 3. Preventive Maintenance Standard: Main Machine + ADF Plotter Copy Paper (40 to 128 g/m Front Side (mm) Reverse Side (mm) More than 279 Up to 279 More than 279 Up to 279 ±0.5 mm/200 ±0.5 mm/100 ±0.5 mm/200 ±0.5 mm/100 ADF: Copy Paper (40 to 128 g/m Front Side (mm) Reverse Side (mm)

  • Page 463: Lcit

    Paper Transfer Quality Standards Method 1. Make a 1:1 copy of the S-2-1 chart with normal paper. 2. Use the scale to measure the left and right registration marks at the leading edge. LCIT Registration Leading edge registration 0±2 mm (±1 mm variation per job) Horizontal registration 0±2 mm Skew...

  • Page 464: Pm Parts Settings

    3. Preventive Maintenance PM Parts Settings Before Removing Old PM Parts 1. Enter the SP mode. 2. Output the SMC logging data with SP5990-004. 3. Press the PM parts counter reset button in the PM Parts display before you turn the power off. 4.

  • Page 465: Power Switch

    4. Replacement and Adjustment Power Switch Push Switch The power button of this machine has been changed to a push-button switch from the conventional rocker switch. The push switch has characteristics and specifications different from the rocker switch. Care must be taken when replacing and adjusting parts. Characteristics of the Push Switch (DC Switch) 1.

  • Page 466: Shutdown Method

    4. Replacement and Adjustment • Automatic restart deals with cases when you accidentally unplugged the AC power cord or unexpected power outages. By keeping the power flag ON, after the resumption of power, the machine will start up automatically. In rare cases, when you reconnect the AC power cord to a power outlet, the machine does not start automatically.

  • Page 467: Forced Shutdown

    Power Switch • To start the machine, press the main power switch. However, if you press the main power switch between the beginning and the end of a shutdown, the machine will not start. Forced Shutdown In case normal shutdown does not complete for some reason, the machine has a forced shutdown function.

  • Page 468: Before You Begin

    4. Replacement and Adjustment Before You Begin • Before servicing the machine, always turn the machine off and disconnect the power cord. • After replacing parts, make sure that all removed harnesses are connected again and secured in their clamps. •...

  • Page 469: Transfer Belt Unit

    Before You Begin 2. Make sure that the drum unit is set in position and the drum stay is secured with the screw before the main switch is turned on. 3. If the drum unit is loose, poor contact of the drum connectors may cause electrical noise, resulting in unexpected malfunctions (RAM data change is the worst case).

  • Page 470: Development

    4. Replacement and Adjustment 2. Clean the charge corona casing with water first to remove NOx based compounds. Then clean it with alcohol if any toner still remains on the casing. 3. Clean the end block with a blower brush first to remove toner and paper dust. Then clean with alcohol if any toner still remains.

  • Page 471: Fusing Unit

    Before You Begin 3. Before disassembling the cleaning section, place a sheet of paper under it to catch any toner falling from it. Fusing Unit 1. After installing the end thermistor, make sure that it is in contact with the hot roller. 2.

  • Page 472: Proximity Sensor

    4. Replacement and Adjustment 2. To avoid breaking LED connectors or harnesses, be careful about inner cover removal. 3. After the screws are removed, the cover should be pulled away partially so the LED can be disconnected before the cover is pulled away completely. Proximity Sensor 1.

  • Page 473: Psu Precautions

    Before You Begin 2. This sensor works on the principle of detection of body heat. The sensitivity of the detection device is affected by both ambient temperature and the amount and type of clothing worn by the operator. PSU Precautions 1.
  • Page 474 4. Replacement and Adjustment • Never leave the covers off during machine testing, or while the machine is idle during servicing. • To avoid personal injury, always handle the PSU by its edges. • Never touch the back of the board. •...

  • Page 475: Important Sp Codes: Machine Information, Servicing

    Before You Begin The photo below shows the danger zone, and the location and address of each condenser where residual charge remains. Important SP Codes: Machine Information, Servicing Here are quick summaries of SP codes that give you useful information about the machine, and some common SP codes you will need during maintenance.
  • Page 476 4. Replacement and Adjustment Item SP No. Function Machine serial number 5811 Use this SP to display the serial number for the machine and BICU. ROM number 7801 Displays ROM number and firmware information for main machine and all other connected devices. SC history 7403 Displays the following information about the most...
  • Page 477 Before You Begin Item SP No. Function Forced toner supply 2207 Rotates the toner bottle to supply toner to the toner supply unit. Use to determine if toner supply is operating correctly. If forcing toner supply with this SP does not darken the image, then toner supply is not operating correctly.

  • Page 478: Special Tools And Lubricants

    4. Replacement and Adjustment Special Tools and Lubricants Special Tools Part No. Description A0069104 Scanner Positioning Pin (4 pcs./set) A2929500 Test Chart – S5S (10 pcs./set) A0299387 Digital Multi-meter – FLUKE 87 VSST9500 Test Chart – S5S – DF (10 Sheets/Set) G0219350 Loop Back Connector B6455010...

  • Page 479: Covers

    Covers Covers Front Door 1. Open the front door. 2. At [A] locate the hinge bracket plunger [B]. 3. While supporting the door with one hand, press the hinge plunger [A] down to release the door, and then pull the door [B] slightly away from the corner of the machine.

  • Page 480: Right Covers

    4. Replacement and Adjustment 4. Disconnect the brackets at the bottom of the door and pull it away from the machine. Right Covers Right Upper Cover 1. Remove the LCIT entrance guide cover [A].
  • Page 481 Covers 2. Disconnect the right upper cover [B]. 3. Open bypass tray [A]. 4. Pull the right upper cover [B] down and away from the machine. 5. Close the bypass tray.
  • Page 482 4. Replacement and Adjustment To re-attach right upper cover 1. First, insert the tabs at the front edge [A] and rear edge [B] of the tray into the slots of the frame. 2. Open the bypass tray [A]. 3. Position the cover over the bypass tray. 4.

  • Page 483: Right Lower Cover

    Covers Right Lower Cover 1. Disconnect the cover. 2. Lift the cover slightly and pull it away. To re-attach the right lower cover 1. Insert the front tab [1] and rear tab [2] into the holes of the cross-stay, and then set the cover.

  • Page 484: Rear Covers

    4. Replacement and Adjustment Rear Covers Rear Upper Cover 1. Locate the three shoulder screws at the bottom edge of the cover. 2. Loosen these screws slightly. Do not remove them. 1. Disconnect the cover at the right upper corner [A] and left upper corner [B]. Remove these screws.

  • Page 485: Rear Lower Cover

    Covers 2. Pull the cover up slightly and pull it away. Rear Lower Cover 1. Locate the two shoulder screws at the bottom edge of the cover. 2. Loosen these screws slightly. Do not remove them.

  • Page 486: Left Covers

    4. Replacement and Adjustment 3. Remove the screws at each upper corner of the cover. 4. Remove the cover. Left Covers Left Upper Cover 1. Remove the cover.
  • Page 487 Covers 2. On the rear edge of the cover [A] disconnect the tab from its post. 3. Disconnect the tabs on the side.
  • Page 488 4. Replacement and Adjustment 4. Remove the cover. To re-attach the left upper cover: 1. First, engage the tab and post [A] at the rear edge of the cover.

  • Page 489: Left Lower Cover

    Covers 2. At the front, set the cover so it will slide up under the edge [A] of the covers above. 3. Set the tabs into knockouts on the cross-stay [A]. 4. Re-attach the screws. Left Lower Cover 1. Disconnect the cover. 2.

  • Page 490: Controller Box Cover Plate

    4. Replacement and Adjustment Controller Box Cover Plate Many procedures require that you open the controller box plate so you can access the BICU, controller board, and HDD. 1. Remove the rear upper cover. page 482 2. Disconnect the controller box plate. 3.
  • Page 491 Covers 4. With the plate removed, you can see [1] BICU, [2] controller board, and [3] HDD. Re-assembly 1. Set the bottom edge of the cover plate on the front bottom edge of the controller box. 2. Make sure that all the metal tabs line up with their holes on the frame. 3.

  • Page 492: Controller Box

    4. Replacement and Adjustment 4. Check the tabs and make sure that they are inserted in their holes. Controller Box Many procedures require that you open the controller box so you can access the back of the machine. 1. Remove the rear upper covers. page 482 2.
  • Page 493 Covers 5. Disconnect the edge of the controller box. 6. Lift the handle [A] off of its hook on top of the box, and then pull it toward you. 7. Swing the controller box open.

  • Page 494: Iob Bracket

    4. Replacement and Adjustment IOB Bracket Some procedures require that you access the components behind the IOB. You do not have to remove the IOB. The IOB support bracket is set on hinges so it can swing open to the left. 1.
  • Page 495 Covers 3. Swing the bracket open. 4. If you need more space to work, disconnect the left upper corner of the IOB. 5. The bracket can swing open farther.
  • Page 496 4. Replacement and Adjustment 6. If you need still more space to work, lift the IOB bracket off its hinges at the top [1] and bottom [2]. 7. Check the bottom corner and confirm that the bottom hinge [2] is out of the hole. •...
  • Page 497 Covers 9. With the controller box open and the IOB bracket lowered, you now have full access to all the components on the back of the machine.

  • Page 498: Operation Panel

    4. Replacement and Adjustment Operation Panel Operation Panel Removal Follow this procedure to replace the operation panel unit. 1. Turn off the machine and disconnect the power cord. 2. Disconnect the front edge cover. 3. Bend the ends of the cover toward you slightly to disengage the tabs on the ends, and then remove the cover.
  • Page 499 Operation Panel 5. Cover the exposure glass [A] to protect it. 6. Lift the disconnected operation panel. 7. Lay the operation panel on the machine upside down. 8. Disconnect the cable and ground wire.
  • Page 500 4. Replacement and Adjustment 9. Disconnect operation panel cover. 10. Lift the operation panel cover up and remove it. 11. Before you replace the operation panel unit, first look in the window of the old unit and check the DIP SW settings.
  • Page 501 Operation Panel 12. Turn the unit so you can read the numbers of the DIP SW. • The DIP SW settings are different, depending on the machine. • The DIP SW settings of the new unit must match the settings of the old unit. •...

  • Page 502: Lcd, Touch Panel Replacement

    4. Replacement and Adjustment 14. Before handling the new operation panel, touch a metal surface with your bare hands and your screwdriver to discharge any static electrical charge. • Keep the screwdriver and any other metal tools away from the boards of the new operation panel unit.
  • Page 503 Operation Panel 4. Rotate the operation panel [A] as shown. This orients the unit for the remainder of the procedure. 5. Remove base bracket [A] . 6. Disconnect the CPU.
  • Page 504 4. Replacement and Adjustment 7. Remove CPU board from microcomputer board. 8. Raise the fastener on the connector at the CPU. 9. Disconnect CPU board [A].

  • Page 505: Microcomputer Board

    Operation Panel Microcomputer Board 1. Slide out the black collar to unlock the flat connector, and then disconnect the FFC. 2. Remove microcomputer board [A].

  • Page 506: Lcd And Touch Panel

    4. Replacement and Adjustment LCD and Touch Panel 1. Remove speaker [A] (x2). 2. Raise the fastener of the LCD I/F cable...
  • Page 507 Operation Panel 3. Disconnect the LCD I/F cable. 4. Undo the tapes holding the microphone harness.
  • Page 508 4. Replacement and Adjustment 5. Disconnect the LCD. 6. Separate the touch panel [A] and LCD [B]. 7. After reassembly, do the LCD panel check and calibration procedures. LCD, Touch Screen Check and Calibration...

  • Page 509: Scanner Unit

    Scanner Unit Scanner Unit Before You Begin There is no SIOB (Scanner Interface Board) in this machine. The functions of the SIOB of the previous machine are controlled by the BICU. Both harnesses of the scanner unit connect directly to the BICU in the controller box on the back of the machine.
  • Page 510 4. Replacement and Adjustment 4. At the left side [A] remove the left edge plate. 5. At the back of the scanner unit, remove the rear edge plate (no screws). 6. At the front, remove the front edge plate.
  • Page 511 Scanner Unit 7. Disconnect the operation panel cover but do not remove it. 8. Slide the panel forward slightly and then stop. 9. Loosen (do not remove!) the bottom screws of the rear upper cover [A].
  • Page 512 4. Replacement and Adjustment 10. Disconnect the rear upper cover at the right rear corner [A] and left rear corner [B]. 11. Remove rear upper cover...
  • Page 513 Scanner Unit 12. Disconnect the rear cover plate. 13. Slide the cover off in the direction of the arrow. 14. Disconnect the base of the scanner unit at each corner.
  • Page 514 4. Replacement and Adjustment 15. At the back of the machine, you must disconnect the triple-harness cable [1] and the I/F cable [2]. 16. Disconnect the I/F cable [B] from the rear panel.
  • Page 515 Scanner Unit 17. Disconnect the I/F cable. 18. Disconnect the triple harness [A] from the frame. 19. Disconnect the three harnesses [B]. 20. At the right rear upper corner, free the triple-harness [A] and I/F cable [B].
  • Page 516 4. Replacement and Adjustment 21. Below rear right corner [A], open the clamp, and then pull out the I/F cable. 22. Next, free the I/F cable above rear right corner [A].
  • Page 517 Scanner Unit 23. Pull the triple harness out through the corner [A]. 24. Lay the triple harness and I/F cable across the exposure glass [A]. 25. On the left edge of the scanner unit [B], raise the elastic handle. 26. Grip the scanner unit by the handle on each side, and then lift it out and remove it.

  • Page 518: Exposure Glass

    4. Replacement and Adjustment 27. Lay the scanner unit on a flat, clean surface. Reassembly 1. When you re-attach the PCB cover plate [A], first set the tabs on the rail below. Make sure each tab is engaged with the rail. 2.
  • Page 519 Scanner Unit 3. On the right [A], remove the right edge plate. 4. At [A] near the rear edge of the exposure glass, remove rear scale. 5. At the top left side of the machine [A] remove the u-bracket.
  • Page 520 4. Replacement and Adjustment 6. Remove the exposure glass, and then lay it on a flat, clean surface. 7. Lift out the exposure glass and left scale together. • The left scale is attached to the exposure glass with double-sided tape. Do not separate the left scale and the exposure glass unless you are going to replace a broken glass.

  • Page 521: Contact Glass

    Scanner Unit 10. Hold the exposure glass so the >PS< notation is at the upper left corner, and then set the glass in the machine. 11. Make sure the >PS< notation [A] is at the upper left corner, and that the hole on the end is snug over the boss.
  • Page 522 4. Replacement and Adjustment 2. Remove the contact glass. • Step strip [A] is attached to the top of the contact glass. • The right side of the contact glass [B] is fastened by double-sided tape below its right edge. 3.
  • Page 523 Scanner Unit 4. Peel the back from the double-sided tape strip. 5. Set the one end of the tape at the rear [A] aligned with the line marker, and then set the other end of the tape at the front [B] at its line marker. 6.
  • Page 524 4. Replacement and Adjustment 10. Press down gently on the right edge of the glass onto the tape below it. 11. Re-install the exposure glass, rear scale, and left edge cover. 12. Locate the notch [A] on the rear end of the right edge cover. 13.

  • Page 525: Convert From Non-Contact To Contact Scanning Configuration

    Scanner Unit Convert from Non-Contact to Contact Scanning Configuration The step strip mounted to the left of the contact glass keeps the surface of the original out of contact from the glass. This is the standard configuration. However, with the replacement of two parts this configuration can be modified to revert to the old method with the surface of the original in contact with the glass as it passes.
  • Page 526 4. Replacement and Adjustment 3. Note that the tabs [A] on the ends of the non-contact scanning guide plate (just removed) are black, and the tabs [B] (replacement) of the contact-type are white. 4. Attach the contact-type scanning guide plate [A] (white tabs). 5.

  • Page 527: Contact Glass Cleaning

    Scanner Unit Contact Glass Cleaning 1. Carefully, peel the black step strip [A] away from the contact glass. 2. Dampen a clean cloth with alcohol and clean the contact glass. Lens Block Cover 1. Remove exposure glass. page 516 2. The lens block cover is on the right side of the scanner unit. 3.
  • Page 528 4. Replacement and Adjustment 4. Raise the lens block cover and remove it. Under the lens block cover: Original Width Sensors Lens • Never remove a paint-locked screw [1] on the lens block.

  • Page 529: Original Width Sensors

    Scanner Unit Original Width Sensors 1. Remove the exposure glass. page 516 2. Remove the lens block cover. page 525 3. Free the harness of the left sensor. 4. Press the back of left sensor [A] to release it, and then disconnect it.
  • Page 530 4. Replacement and Adjustment 5. Lay the sensor on a flat, clean surface. 6. Press the back right sensor [A] to release it, and then disconnect it.

  • Page 531: Lens Block

    Scanner Unit 7. The original width sensors are identical and interchangeable. Lens Block 1. Remove the exposure glass. page 516 2. Remove the lens block cover. page 525 3. Disconnect original sensors [A]. 4. Disconnect SBU [B].
  • Page 532 4. Replacement and Adjustment 5. The FFC at the front edge of the SBU is locked in place by a sliding collar [A]. 6. Slide the collar [B] out to release the FFC. 7. Disconnect the FFC.
  • Page 533 Scanner Unit 8. Disconnect the lens block. • Never loosen or attempt to remove a paint-locked screw on the lens block.
  • Page 534 4. Replacement and Adjustment 9. Remove the lens block, and then lay it on a flat, clean surface. • The lens block is replaced as a set. Do not remove the SBU. Re-installation • Reattach the FFC to the SBU before you re-install the lens block. 1.

  • Page 535: Exposure Leds (Exposure Lamp)

    Scanner Unit 4. Confirm that the FFC is locked and straight. 5. After reassembly, do the scanner and printer adjustments. page 985 Exposure LEDs (Exposure Lamp) • The Exposure LEDs (exposure lamps) are comprised of a pair of LED arrays mounted on separate brackets.
  • Page 536 4. Replacement and Adjustment 1. You may need to move the Exposure LED bracket slightly so you can see the FFC of the left bracket at the rear. 2. Disconnect FFC at the rear end of the left Exposure LED. 3.
  • Page 537 Scanner Unit • Never touch the window surface of the Exposure LED with bare fingers. 6. Remove the left Exposure LED bracket with LED attached. 7. Lay the left Exposure LED bracket on a flat, clean surface. 8. Turn the bracket over, and disconnect the LED PCB.
  • Page 538 4. Replacement and Adjustment 9. Separate the LED PCB and bracket. 10. Lay the LED PCB flat with the LEDs facing up. Right Exposure LED 1. You may need to move the Exposure LED bracket [A] slightly so you can see the FFC of the right bracket at the front [B].
  • Page 539 Scanner Unit 3. Disconnect the front end [B] of the right Exposure LED bracket. • Never touch the window surface of the Exposure LED with bare fingers. 4. Remove the right Exposure LED bracket with LED attached. 5. Lay the right Exposure LED on a flat, clean surface.
  • Page 540 4. Replacement and Adjustment 6. Turn the bracket over, and disconnect the LED PCB. 7. Separate the bracket and LED PCB. 8. Lay the LED PCB flat with the LEDs facing up. Reassembly 1. Inspect replacement Exposure LEDs for dust or other particles and clean with a blower brush before installation.
  • Page 541 Scanner Unit 2. Before installation, make sure the LED PCB is perfectly flat against the bracket. 3. To install the bracket, hold the bracket up at a slight angle [A] and then lower it [B] so it locks against the frame..

  • Page 542: Scanner Motor

    4. Replacement and Adjustment 4. Be sure to re-attach the mylar completely over the cutout if you detached it. Scanner Motor 1. Remove the exposure glass. page 516 2. The scanner motor is at the right front corner of the scanner unit. 3.
  • Page 543 Scanner Unit 5. Remove the right upper cover. 6. On the right side of the machine, disconnect the development unit fans. 7. Disconnect the development unit fan bracket [A].
  • Page 544 4. Replacement and Adjustment 8. Remove the development unit fan bracket with fans attached. 9. Disconnect the cross-stay. 10. Lower the cross-stay and let it hang. It is not necessary to remove it. 11. Disconnect the scanner motor bracket.
  • Page 545 Scanner Unit 12. Inside the scanner unit, disconnect the left end [A] of the drive belt. 13. Disconnect the right end [B] of the drive belt from the motor. 14. Disconnect motor [A] and then remove the bracket with motor attached.
  • Page 546 4. Replacement and Adjustment 15. Disconnect motor bracket. 16. Separate motor and bracket. To re-attach the cross-stay 1. Set the front hook [A] and rear hook [B] into the holes provided so the stay is perfectly straight.

  • Page 547: Scanner Hp Sensor

    Scanner Unit Scanner HP Sensor 1. Remove the scanner unit and set it on the frame of the machine. page 507 • It is not necessary to disconnect the ADF I/F cables at the back of the machine. • Just remove the exposure glass and the four base screws that secure the scanner unit, raise the scanner out of the well, and then set on the frame of the machine.
  • Page 548 4. Replacement and Adjustment 3. Remove the sensor hook plate stopper [A]. 4. Disconnect the sensor [A] from the frame. 5. Lay the sensor on a flat, clean surface.

  • Page 549: Adf Open Sensor

    Scanner Unit ADF Open Sensor 1. Remove the ADF. page 895 2. Disconnect rear flat plate. 3. Remove left edge plate [A]. 4. Remove right top plate.
  • Page 550 4. Replacement and Adjustment 5. Remove rear flat plate. 6. Disconnect scanner HP sensor. 7. Remove the sensor.

  • Page 551: Scanner Wire

    Scanner Unit Scanner Wire Scanner Wire Removal 1. Remove the scanner unit. page 507 2. Disconnect ground wire [1] ( 3. Disconnect the head of the wire [2] from tension bracket 1. 4. Remove spring [3]. 5. Loosen the screw [4] of tension bracket 1. 6.

  • Page 552: Scanner Wire Reinstallation And Scanner Position Adjustment

    4. Replacement and Adjustment Scanner Wire Reinstallation and Scanner Position Adjustment 1. Place the beads [A] on the middle of the wire in the openings in the pulley. 2. Wind the ball end of the wire [B] 4 times. 3. Wind the other end of the wire [C] 5 times. 4.
  • Page 553 Scanner Unit 5. Position the 1st scanner [A] so that the holes are aligned, and insert the positioning pins [B] (x4). 6. Position the 2nd scanner [C] so that its holes are aligned, and insert the positioning pins [D]. 7. Attach the lock bracket [E] to fasten the wire to the 1st scanner. 8.

  • Page 554: Important Sp Codes: Scanner Unit

    4. Replacement and Adjustment 12. Slowly push the scanner left and right to confirm that the wires are engaged correctly. The 1st and 2nd scanners should move smoothly. Important SP Codes: Scanner Unit Here is a list of SP codes related to testing and servicing the scanner unit. Item SP No.

  • Page 555: Laser Unit

    Laser Unit Laser Unit • Turn off the machine and unplug its power cord before performing any procedure in this section. Laser beams can seriously damage the eyes. • This laser unit uses four laser beams produced by a Class IIIb LDA with a wavelength of 653 to 665 nm and intensity of 15 mW.
  • Page 556 4. Replacement and Adjustment • Touch a metal surface to discharge any static electricity from your hands. • The polygon motor rotates at extremely high speed and continues to rotate after switching the machine off. • To avoid damaging the motor, never remove the polygon motor within three minutes of switching off the machine and disconnecting its power plug.

  • Page 557: Polygon Motor

    Laser Unit • An accidental static discharge could damage the laser diode board or other boards under the polygon motor cover. • To prevent damage to a PCB, always touch a metal surface to discharge any static electricity from your hands before you remove a component. Polygon Motor 1.

  • Page 558: Polygon Motor Drive Board

    4. Replacement and Adjustment Polygon Motor Drive Board 1. Remove scanner unit. page 507 2. Remove polygon motor cover. page 553 3. Disconnect the polygon motor drive board. 4. Touch a metal surface to discharge any static charge from your hands. 5.

  • Page 559: Laser Synchronization Detector

    Laser Unit 6. Remove the LD unit. After Reassembly Do this procedure if you replaced the LD unit. 1. Reconnect the machine. 2. Make sure the front door is closed, and then turn the machine on. 3. Go into the SP mode and execute SP2110-005. This automatically downloads the settings to the machine for the new LD unit.
  • Page 560 4. Replacement and Adjustment 4. The laser synchronization detector [A] is inside the right front corner of the machine. • You do not need to remove the development unit fans next to the laser synchronization detector. 5. Loosen the single screw of the laser synchronization detector [A] (do not remove it!). 6.
  • Page 561 Laser Unit 7. Remove the detector. Re-installation 1. Connect the harness to the detector. 2. Slide the cutout on the right edge of the detector behind the screw head [1]. 3. Set the hole [2] onto the point of the boss on the left, and then tighten the screw.

  • Page 562: Laser Unit Alignment

    4. Replacement and Adjustment 4. After replacement of the laser synchronization detector, set SP1002-1 to -7 (Side-to-Side Registration) to their default settings. Laser Unit Alignment This adjustment corrects the parallelogram pattern to the desired rectangular pattern for printing. It does not correct the skew of scanned images.
  • Page 563 Laser Unit 5. On the left [A], loosen the adjustment screw. 6. While watching at the scale [1], use a flathead screwdriver at [2] to move the laser exposure unit left or right on the scale until it is centered on the scale.

  • Page 564: Toner Shield Glass

    4. Replacement and Adjustment • The scale is set for increments of 1 mm. 7. Refer to the illustration below: • If the pattern is skewed at the corner of the leading edge [A], move the unit so it moves the pointer on the scale toward the rear of the machine.
  • Page 565 Laser Unit 3. Locate and remove the metal bracket. 4. Slowly, pull the toner shield glass straight out to remove it.

  • Page 566: Laser Unit Removal

    4. Replacement and Adjustment 5. Lay the glass on a flat, clean surface. Laser Unit Removal 1. Remove the toner shield glass. page 562 2. Remove the scanner unit. page 507 3. First, you must remove top cover [A],...
  • Page 567 Laser Unit 4. Disconnect the left side [A] of the top cover. 5. Disconnect the front edge [A] of the top cover.
  • Page 568 4. Replacement and Adjustment 6. Disconnect right side [A] of the top cover. 7. Disconnect right rear corner [A] of top cover.
  • Page 569 Laser Unit 8. Release the harnesses attached to the back of the cover [A]. 9. Remove the top cover.
  • Page 570 4. Replacement and Adjustment 10. At the front, right corner [A] of the laser unit disconnect the laser synchronization unit. 11. Disconnect the left side of the unit at [A] and [B].
  • Page 571 Laser Unit 12. The shielded cable is fastened to the unit frame with a metal clamp [1]. 13. Remove the clamp [2] and free the shielded cable. 14. Disconnect the LD unit [3]. 15. Disconnect the left side of the laser unit [A]. 16.
  • Page 572 4. Replacement and Adjustment 17. Remove the laser unit and lay it on a flat, clean surface. Reinstallation 1. When you install the laser unit in the machine, first set the front right corner under support [A].
  • Page 573 Laser Unit 2. On the left, before you re-attach the screw at [1], shift the notch on the left side of the unit [2] so it is aligned with the middle line of the scale below. 3. Insert a screwdriver [3] into the plate to hold the unit in place as you re-attach the screws. 4.
  • Page 574 4. Replacement and Adjustment 5. After you set the top plate on the unit, make sure that the harnesses on the left are not pinched under the plate. 6. Reconnect the machine. 7. Make sure the front door is closed, and then turn the machine on. 8.

  • Page 575: Ld Safety Switches

    Laser Unit LD Safety Switches In this machine the mechanism that makes the laser unit operational is a 24V1 line interrupted using a 5VS relay and then 24VS is dropped to +5VS1 using a regulator. To ensure the safety of the machine operators and service technicians, one switch prevents the laser beams from switching on accidentally.

  • Page 576: Drum Unit

    4. Replacement and Adjustment Drum Unit Corona Unit Corona Grid 1. Open the front door. 2. Pull the toner bottle holder out and swing the bottle to the right. 3. Disconnect the charge corona unit. 4. Without touching the wire mesh on top of the unit, pull the charge corona unit out of the machine. 5.

  • Page 577: Charge Wire

    Drum Unit • Always lay the unit down with the wire grid facing up. • Never lay the unit down with the grid facing down. 6. Remove grid [A]. Charge Wire 1. Remove the corona grid. (See procedure above.) 2. Remove terminal plate [A]. 3.

  • Page 578: Cleaning Pad

    4. Replacement and Adjustment • Never touch the charge corona wire with bare hands. Always protect it from dust, oil, etc. • Never bend or knot the wire. Charge will not distribute evenly on a bent wire. Cleaning Pad 1. Remove the charge wire. page 574 2.

  • Page 579: Corona Wire Cleaning Motor

    Drum Unit 2. After replacing the charge corona wire, make sure that the wire cleaner pads are engaged correctly with the wires. Corona Wire Cleaning Motor 1. Open the front door. 2. Swing the toner bottle holder to the right. 3.
  • Page 580 4. Replacement and Adjustment • Always lay the unit down with the wire grid facing up. • Never lay the unit down with the grid facing down. 7. Disconnect the front plate [A]. 8. Free the snap plate [B]. 9. Remove the motor. 10.

  • Page 581: Corona Power Pack

    Drum Unit Corona Power Pack 1. Remove the rear upper and rear lower cover. page 482 2. Open the controller box. page 490 3. The corona power pack is located behind the flywheel. 4. Remove the flywheel and rear center stay. 5.
  • Page 582 4. Replacement and Adjustment 6. Disconnect the center stay. 7. Slowly and carefully, lower the center stay [A] away from the corner plate [B] of the IOB bracket below.
  • Page 583 Drum Unit • The bracket on the bottom of the center stay provides the pivot point for the hinge at the upper left corner of the IOB bracket. The arm of the IOB bracket is soft and bends easily. 8. Disconnect the power pack. 9.

  • Page 584: Drum

    4. Replacement and Adjustment 10. Separate the power pack from the bracket. Drum Drum Unit Removal 1. Remove the development unit. page 623 2. Remove the corona unit. page 574 3. Grasp the front of the drum unit by the small handle, and then pull the drum unit out of the machine.

  • Page 585: Drum Removal

    Drum Unit 4. Lay the drum unit on a flat, clean surface. Drum Removal 1. Remove the drum unit. page 623 2. Remove front screw and bracket.
  • Page 586 4. Replacement and Adjustment 3. Remove rear screw. 4. Open the drum unit. 5. Without touching the surface of the drum, grasp the drum by each end and lift it out of the unit.
  • Page 587 Drum Unit 6. For reassembly, note the shape of the rear end of the drum. 7. Cover the drum with some paper to protect its surface from strong light.
  • Page 588 4. Replacement and Adjustment • Never touch the surface of the drum. • Never attempt to clean the surface of the drum with alcohol or any other type of organic solvent. • Never place the drum where it would be exposed to strong light, or sunlight. 8.

  • Page 589: Ptl (Pre-Transfer Lamp)

    Drum Unit 13. After replacing the drum, do SP2962 (Adjustment of Drum Conditions). PTL (Pre-Transfer Lamp) 1. Remove the drum unit and drum. page 582 2. The PTL bracket is held in place by two screws [A] and [B]. Screw [B] is a shoulder screw. This screw must be installed at the same position.
  • Page 590 4. Replacement and Adjustment 7. At the center, disconnect the PTL. 8. Roll the PTL bracket out from under the edge of the frame. 9. Separate the PTL from its bracket.

  • Page 591: Ql (Quenching Lamp)

    Drum Unit 10. Lay the PTL on a flat, clean surface. Re-assembly 1. Set the PTL in its bracket. 2. Rock the edge of the bracket up under the edge of the frame. • If the edge of the bracket is not under the edge of the frame, the PTL and its bracket will not be perfectly flat against the frame, and you will not be able to re-attach the screws and the connector.
  • Page 592 4. Replacement and Adjustment 3. At the center, disconnect the QL [A]. 4. At the center, push back the hook [A] to release the quenching lamp, and then slide out the end of the QL [B]. 5. Lift out the QL.

  • Page 593: Potential Sensor

    Drum Unit 6. Use only a blower brush to clean the quenching lamp. Potential Sensor 1. Remove the drum unit. page 582 2. Disconnect the potential sensor bracket.
  • Page 594 4. Replacement and Adjustment 3. Pull the bracket forward [A] to detach the rear end of the bracket from the machine, and then pull it out [B]. 4. Lay the potential sensor bracket on a flat, clean surface. 5. The potential sensor power pack [A] is on the end of the bracket, and the potential sensor [B] is on the opposite side.
  • Page 595 Drum Unit 6. Free the black harness. 7. Push the harness [A] through the bracket, and then pull the connector [B] through the hole. 8. Disconnect the potential sensor.
  • Page 596 4. Replacement and Adjustment 9. On the other end of the bracket, disconnect the power pack cover. 10. Remove cover [A] and power pack [B]. 11. The potential sensor and power pack are always replaced together.

  • Page 597: Cleaning Filter

    Drum Unit Re-assembly 1. The end of the potential sensor bracket [A] is inserted into the cut-out [B] on the rear panel. 2. After replacing the drum potential sensor, go into the SP mode and make sure that SP3901 is on, and then do SP2962 (Adjustment of Drum Conditions).

  • Page 598: Drum Cleaning Blade

    4. Replacement and Adjustment 3. Lift out the filter. 4. After replacing the filter, make sure that its edges are perfectly flat against the unit. Drum Cleaning Blade 1. Remove the drum unit and drum. page 582 2. Disconnect the blade.

  • Page 599: Cleaning Brush

    Drum Unit 3. Remove the blade. 4. Clean the blade edge carefully with only a soft, clean cloth. • Handle the blade carefully to avoid nicking its edge. • New blades are treated with special setting powder, so avoid touching the edge of a new cleaning blade.
  • Page 600 4. Replacement and Adjustment 4. Remove the inner bushing. 5. Pull the shaft of the cleaning brush toward the rear to disengage the coupling on the end of the shaft from its pin, and then pull the brush out. • Avoid touching the cleaning brush with bare hands.
  • Page 601 Drum Unit Re-assembly 1. The pin [A] fits into the slot of the coupling [B] on the end of the cleaning brush. 2. After replacing the cleaning brush, use a blower brush and clean the ID sensor to make sure that it is free of toner.

  • Page 602: Pick-Off Pawls

    4. Replacement and Adjustment Pick-off Pawls 1. Remove the drum unit and drum. page 582 2. Remove the pick-off pawl bracket with the pawls attached. 3. Disconnect the pick-off pawls. Re-assembly 1. Each pawl must be positioned as shown.

  • Page 603: Id Sensor

    Drum Unit ID Sensor 1. Remove the drum unit and drum. page 582 2. Remove the pick-off pawl bracket. 3. Raise the drum unit [A] slightly so you can see the sensor [B]. 4. Disconnect the sensor.

  • Page 604: Toner Collection Bottle

    4. Replacement and Adjustment 5. Remove the sensor. 6. Re-assemble the machine. 7. Connect the machine, turn it on, and go into the SP mode. 8. Do SP3901 and make sure that it is on (default), and then do SP2962 (Adjustment of Drum Conditions).

  • Page 605: Ozone Filters

    Drum Unit 4. Detach the bottle from the base clamp and replace it with an empty bottle. Ozone Filters 1. On the back of the machine, remove the cover of the ozone filter box.

  • Page 606: Optics Dust Filter

    4. Replacement and Adjustment 2. Slide the cover off. 3. Remove the ozone filters and replace them with new ones. Optics Dust Filter 1. At the right rear corner of the machine [A] remove the cover bracket with filter attached. 2.

  • Page 607: Internal Dust Filter

    Drum Unit Reinstallation 1. Set the tabs on the bottom edge of the filter into the notches provided on the bottom of the filter frame. 2. Make sure that the edges of the filter are flat and even with the edges of the frame. Internal Dust Filter 1.
  • Page 608 4. Replacement and Adjustment 4. Remove the filter. 5. Lay the filter on a clean, flat surface. 6. Clean the filter with a vacuum cleaner.

  • Page 609: Toner Bottle Fan

    Drum Unit Toner Bottle Fan 1. Open the front door. 2. Remove the left upper inner cover. 3. With the cover removed you can see the duct of the toner bottle fan. 4. Remove the scanner unit. page 507 5. Disconnect the left edge [A] of the laser unit cover. 6.
  • Page 610 4. Replacement and Adjustment 7. Disconnect the right edge [A] of the cover. 8. Disconnect the right rear corner [B] of the cover. • Do not loosen either screw [C] below. These screws are used to adjust the position of the scanner unit.
  • Page 611 Drum Unit 10. Pull the cover [A] away from the front edge of the machine [B] . (You do not need to remove.) 11. Disconnect the toner bottle motor.
  • Page 612 4. Replacement and Adjustment 12. Push in the tab release [A] on the right side of the motor bracket. 13. Rotate the motor [B] straight up, and then remove the motor bracket. 14. Disconnect the motor bracket.
  • Page 613 Drum Unit 15. Separate the motor and bracket. Re-assembly 1. Hold the motor [A] over the position where you removed it, and then rotate it straight down. 2. Check the front of the machine under the operation panel, and confirm that the duct [B] is aligned straight with its cutout.

  • Page 614: Drum Motor

    4. Replacement and Adjustment 5. Once again, check the alignment of the duct at the front of the machine and confirm that it is straight. 6. Reassemble the machine. Drum Motor 1. Remove rear covers. page 478 2. Open the controller box [A]. page 490...
  • Page 615 Drum Unit 3. Disconnect the IOB bracket [A]. page 492 4. Remove the flywheel. 5. Remove the flywheel sprocket.
  • Page 616 4. Replacement and Adjustment 6. Remove the small gear. (This gear is black in the D223/D224, and white in the D225.) 7. Remove the lower gear (This gear is black in the D223/D224 and white in the D225.) 8. Remove the large gear.
  • Page 617 Drum Unit 9. Note the configuration of the 2-direction timing belt. • Swinging pulley arm [1] is up. • Tan side of the belt is facing out at [2]. • Back side of the belt is facing out at [3]. 10.
  • Page 618 4. Replacement and Adjustment 12. On the face of the motor bracket, remove spring [A]. 13. Loose screw [B] to release tension on the drive belt. 14. Remove drive belt. 15. Disconnect right upper arm [A] of the motor bracket.
  • Page 619 Drum Unit 16. Disconnect right edge [B] of the bracket. 17. Disconnect lower left arm [A] of the motor bracket. 18. Disconnect top edge [B] of the bracket. 19. Remove bracket [A] with motor attached. 20. Lay the bracket and motor [B] on a flat, clean surface.
  • Page 620 4. Replacement and Adjustment 21. Disconnect the support bracket. 22. Pull shaft and coupling through the bracket. 23. Disconnect motor at [A] and [B].
  • Page 621 Drum Unit 24. Separate the motor and base motor bracket. Re-assembly Follow this procedure to re-set the 2-direction drive belt. 1. Pick up the hanging belt [1] and pull it straight out. 2. Push swinging pulley [2] up. 3. Thread the black side of the upper half of the belt [3] to the raised pulley...

  • Page 622: Important Sp Codes: Drum Unit

    4. Replacement and Adjustment 4. Check the configuration of the belt and pulleys. Important SP Codes: Drum Unit Here is a list of SP codes related to testing and servicing the drum and components around the drum. Item SP No. Function Drum condition display (LD level) 3902-5...
  • Page 623 Drum Unit Item SP No. Function Drum condition display (Vd) 3902-2 Displays drum dark potential, the standard potential, electrical potential of the black areas after exposure. Drum condition display (Vg) 3902-4 Displays the charge grid voltage resulting from the latest Vd adjustment. Drum condition display (Vh) 3902-3 Displays standard halftone drum potential,...
  • Page 624 4. Replacement and Adjustment Item SP No. Function Potential sensor replacement 2962 After replacement, do SP3901 to confirm that auto process control is on and operating, and then do SP2962 to execute process control manually for the new sensor. This SP2962 executes only if SP3901 is on (enabled).

  • Page 625: Development Unit

    Development Unit Development Unit Development Unit Removal and Re-Installation Removing the Development Unit 1. If the LCIT is connected to the right side of the machine, disconnect it and pull it away. 2. Prepare a clean, flat surface for the development unit. 3.
  • Page 626 4. Replacement and Adjustment 5. Remove lock screw [A]. 6. The toner bottle holder [B] springs open slightly as soon as the screw is removed. 7. Push the front door slightly to the right, and then swing the holder out as far as it will go.
  • Page 627 Development Unit • The door must be completely open. If it is not, then it will block removal of the development unit. • The LCIT must be disconnected from the right side of the machine to allow the front door to open completely.
  • Page 628 4. Replacement and Adjustment 12. On the right [A] disconnect the development unit [A]. 13. Slip the development unit [A] to the right. 14. Push the development unit [A] slightly to the right, and then pull the unit [B] straight out of the machine.

  • Page 629: Separating The Development Unit And Toner Hopper

    Development Unit 15. Lay the development unit on the prepared surface. Separating the Development Unit and Toner Hopper 1. At the front end of the unit, disconnect the pressure release tube. • Only the D225 Model has this pressure release tube. This step is not required for the D223/ D224 models.

  • Page 630: Re-Installing The Development Unit

    4. Replacement and Adjustment 2. Disconnect the toner hopper. 3. Rotate the toner hopper slightly as you lift it. 4. Remove the toner hopper and set it aside. Re-installing the Development Unit Pay attention to these important points as you re-install the development unit.
  • Page 631 Development Unit 1. Hold the hopper perfectly level when re-attaching it, to prevent toner from entering the rails of the development filter. 2. To re-assemble the top and bottom half of the development unit, first allow the bottom half [A] to tip slightly forward.
  • Page 632 4. Replacement and Adjustment 6. Slip the unit slightly to the right as you push it slowly back into the machine. 7. Push the development unit in until it stops, and then push it to the left. 8. You should see the pin through the oval hole as shown below. This means the unit is locked in the correct position.
  • Page 633 Development Unit 9. The horizontal pin must be through the hole and lapped over the plate as shown below on the left. • If the pin does not slide over the plate as shown above on the left, turn the front gear of the development unit counter-clockwise and try again.
  • Page 634 4. Replacement and Adjustment 11. You must remember to lower the supply pipe shutter so the pipe is open. • The shutter must be down. If it remains up, you will not be able to close the toner bottle holder and the front door.

  • Page 635: Just Replaced Developer

    Development Unit Just Replaced Developer? If you have just replaced the developer, you must initialize the developer immediately after re-installing the development unit. See "Initializing Developer" below. Replacement with a Used Development Unit Do the following procedure if you need to replace the development unit with a unit from another machine for testing.
  • Page 636 4. Replacement and Adjustment 2. Place the development unit [A] on the plastic sheet. 3. Have the disposal bag [B] for the old developer close at hand. 4. Disconnect the hose. (This is necessary only for the D225.) 5. Disconnect the toner hopper.
  • Page 637 Development Unit 6. While holding the hopper perfectly level as you remove it to prevent toner spill, rotate the toner hopper very slightly (10° to 20°) and remove it. 7. Set the toner hopper aside. 8. Spread a sheet of paper on the table. 9.
  • Page 638 4. Replacement and Adjustment 13. Vacuum clean these areas: • Rear side seal [A] • Front side seal [B] • Development roller sleeve and shaft [C] with clean, dry cloth and blower brush 14. Shake the developer packet several times to loosen the developer. 15.
  • Page 639 Development Unit 16. Keep the cut edge with the lot number embossed on it. You will need this number to register the developer lot number on the machine. 17. While turning the knob slowly, pour in one pack of developer from one end of the development unit to the other.

  • Page 640: Re-Installing The Development Unit

    4. Replacement and Adjustment Re-installing the Development Unit Re-assemble the developer unit and toner hopper, and then re-install the unit in the machine. page 623 Initializing the Developer Follow the procedure below precisely to enter the developer lot number, and to initialize the new developer.
  • Page 641 Development Unit 3. Press in the catches on either end to release the entrance seal bracket, then remove it. 4. Remove the side seals from both ends [A] and [B]. 5. Vacuum clean the area, and then attach new seals as shown below.
  • Page 642 4. Replacement and Adjustment 6. Make sure that the seals are attached correctly. • The bottoms of the seals [A] should be fully visible. • The bottom of a seal [B] should not be in the slit. Re-assembly 1. Clean the entrance seal bracket before re-installing it. 2.

  • Page 643: Development Filter

    Development Unit Development Filter 1. Remove the development unit. page 623 2. Separate the development unit and toner hopper. See "Separating the Development Unit and Toner Hopper" in this section. 3. Lift out the filter bracket base. • There are some minor differences in the shape and size of the development filters for the D223/D224 and D225.
  • Page 644 4. Replacement and Adjustment 4. Remove first filter bracket [1]. 5. Remove second filter bracket [2]. 6. Remove rear filter [1].
  • Page 645 Development Unit D223/D224 The filter bracket is one piece. 7. This photo shows the filter bracket base [1], filters [2], and filter brackets [3] removed from the D225. This photo shows the [1] filter bracket base, [2] filters, and [3] filter brackets removed from the D223/D224.

  • Page 646: Td Sensor

    4. Replacement and Adjustment 2. If there is any toner in the rails, wipe them clean before re-installing the bracket case. 3. When installing a new filter, set the filter [A] snug inside the filter case, and then place the case [B] over the top of the filter bracket.
  • Page 647 Development Unit 3. First, free the harness [A]. 4. Disconnect TD sensor [B]. 1. Remove the TD sensor. 2. Clean the port now before you re-attach the TD sensor. 3. Lay the sensor on a flat, clean surface.

  • Page 648: Toner End Sensor

    4. Replacement and Adjustment Re-assembly 1. Be sure to run the harness through the frame as it was originally. 2. If you have just replaced the TD sensor, go into the SP mode. 3. Do SP3901 (Auto Process Control) and make sure that it is on (default). 4.
  • Page 649 Development Unit 3. On the other side of the toner hopper, free the harness. 4. While removing the screws carefully to avoid stripping the holes, disconnect the toner end sensor [A]. 5. Clean the port now before you re-attach the sensor [B].
  • Page 650 4. Replacement and Adjustment 6. Lay the sensor on a flat, clean surface. Re-assembly 1. Pass the harness through the cutout [A] on the edge of the cover. 2. Make sure the harness is not pinched between the side of the toner hopper and the edge of the cover as shown [B].

  • Page 651: Toner Separation Unit

    Development Unit Toner Separation Unit 1. Remove the development unit. page 623 2. Disconnect toner separation unit [A]. 3. Disconnect hose [B] (D225 development unit only) 4. Remove the toner end sensor cover. 5. On the back of the toner hopper, release the long tab of the toner separation unit cover [A], and then remove the toner separation unit [B].
  • Page 652 4. Replacement and Adjustment 6. Lay the toner separation unit on a flat, clean surface. Reassembly 1. Pass the harness through the cutout [A] on the edge of the toner end sensor cover. 2. Make sure the harness is not pinched between the side of the toner hopper and the edge of the cover as shown [B].

  • Page 653: Toner Bottle Motor

    Development Unit Toner Bottle Motor 1. Spread some paper on a flat, clean surface. 2. Open the front door, and then remove the toner bottle. 3. Disconnect the shuttle cover.
  • Page 654 4. Replacement and Adjustment • A washer is attached to the shuttle cover screw in order to prevent the screw from falling into the machine. Turn the screw counter-clockwise only enough turns to remove it. If you loosen the screw too much the washer will fall into the machine. 4.
  • Page 655 Development Unit 7. Locate the small motor harness between the door and toner bottle holder on the right, and then disconnect it. 8. Lift the toner bottle unit off its hinges and lay it on the paper to catch toner spill.
  • Page 656 4. Replacement and Adjustment 9. Disconnect the cover. 10. Disconnect bottom plate [A]. 11. Disconnect toner pan [B], and then remove it.
  • Page 657 Development Unit • The toner pan must be cleaned at every PM interval (300 K). 12. Separate the bottom plate so you can see the motor [A]. 13. Disconnect motor bracket [B] 14. Remove the motor bracket with motor attached [A], and then lay it on a flat, clean surface. 15.

  • Page 658: Development Motor

    4. Replacement and Adjustment 16. Separate the motor and bracket. Development Motor 1. Remove the rear covers. page 482 2. Open the controller box. page 490 3. The used toner pump tube assembly and drive rod [A] block the removal of the motor [B].
  • Page 659 Development Unit 4. Disconnect top of used toner pump assembly [A]. 5. Pull out the stopper on the tube base [A].
  • Page 660 4. Replacement and Adjustment 6. Pull the bottom of the tube [A] up, and then remove the tube pump assembly [B]. 7. Disconnect the motor drive board. 8. Disconnect motor bracket top [A].
  • Page 661 Development Unit 9. Disconnect lower right corner of bracket [B]. 10. Disconnect lower right corner of bracket [A]. 11. Pull out the motor bracket [B] with the motor attached. 12. Lay the motor on a flat, clean surface.

  • Page 662: Development Unit Power Pack

    4. Replacement and Adjustment Re-assembly 1. To hang the motor correctly, insert the hook [1] on the motor bracket into the hole [2] in the frame inside the machine. Development Unit Power Pack 1. Remove the rear upper and lower covers. page 482 2.
  • Page 663 Development Unit 5. Free harness [A]. 6. Disconnect bayonet connectors [B]. 7. Disconnect the bottom edge of the power pack.
  • Page 664 4. Replacement and Adjustment 8. Disconnect the top [A] and bottom [B] of the bracket. 9. Unhook the bracket with the power pack attached and remove it.
  • Page 665 Development Unit 10. Lay the bracket on a flat, clean surface. 11. Remove the cover bracket. 12. Free the connector harnesses. 13. Separate the power pack and bracket.

  • Page 666: Used Toner Collection Unit

    4. Replacement and Adjustment Used Toner Collection Unit Used Toner Collection Unit Removal 1. Remove the rear upper and rear lower covers. page 482 2. Open the controller box. page 490 3. The used toner collection unit [A] is located at the right, rear edge of the main machine. The unit contains three components.
  • Page 667 Development Unit 5. Spread a drop cloth or some paper on a flat clean surface to hold the unit after it is removed from the machine. 6. Disconnect the top [A] and bottom [B] of the toner pump assembly. 1. Grasp the tube [1], drive shaft [2], and base bracket [3] and then remove them together.
  • Page 668 4. Replacement and Adjustment 2. Lay the tube on a flat, clean surface that has been covered with a drop cloth or paper to catch loose toner from the coils. 3. Disconnect the bracket. 4. Pull the unit straight out the back of the machine, and then twist it down and to the right to remove it.

  • Page 669: Toner Collection Motor Sensor

    Development Unit 5. Set the unit on a flat, clean surface. Toner Collection Motor Sensor 1. Remove the used toner collection unit. page 664 2. The toner collection motor sensor [A] is on top of the toner pump assembly. 3. Disconnect gear shaft [B].
  • Page 670 4. Replacement and Adjustment 4. Open the release tabs on the face of both gears [A], then remove them. 5. Remove shaft [B]. 6. Disconnect the sensor, and then remove it.

  • Page 671: Used Toner Collection Motor

    Development Unit Used Toner Collection Motor 1. Remove the used toner collection unit. page 664 2. The used toner collection motor [A] is at the rear of the used toner collection unit. 3. Disconnect the motor [B]. 4. Disconnect the motor from the bracket, and then remove it. Toner Bottle Set Switch, Toner Bottle Full Switch 1.
  • Page 672 4. Replacement and Adjustment Toner Bottle Set Switch 1. Use the tip of a very small screw driver to release the tab at the front bottom edge [A]. 2. Release the tab at the rear top edge [B]. 3. Pull out the switch and disconnect it.
  • Page 673 Development Unit Toner Bottle Full Sensor 1. Remove the top of the unit [A]. 2. Pinch together the side tabs [B] to release the top, and then remove it. 1. Pull the gear and coil [A] out partially. Do not try to remove it. 2.
  • Page 674 4. Replacement and Adjustment 3. Remove screw [A]. 4. Use the tip of a small screwdriver to release the tabs on sensor [B]. 5. Use a pair of small radio pliers to remove the switch.

  • Page 675: Important Sp Codes: Development Unit

    Development Unit Important SP Codes: Development Unit Here is a list of SP codes related to testing and servicing the development unit. Item SP No. Function Developer adjustment mode 2967 Determines whether the amount of toner is checked during auto process control with only the TD sensor. With this feature on, the machine uses the TD sensor only.

  • Page 676: Transfer Belt Unit

    4. Replacement and Adjustment Transfer Belt Unit Transfer Belt Unit Removal 1. Prepare a place to lay the unit by spreading some clean paper or a drop cloth on a flat, clean surface. 2. Remove the drum unit. page 582 •...

  • Page 677: Transfer Belt, Transfer Roller Cleaning Blade

    Transfer Belt Unit Transfer Belt, Transfer Roller Cleaning Blade Transfer Belt Assembly Removal 1. Remove the transfer belt unit. page 674 2. Raise the transfer belt partially by its knob [A]. 3. At the front, disconnect terminal [B]. 4. At the rear, disconnect terminal [C]. 5.

  • Page 678: Transfer Roller Cleaning Blade

    4. Replacement and Adjustment Transfer Roller Cleaning Blade • Never touch the edge of a new transfer roller cleaning blade. • The edge of the blade is dusted with setting powder. • If the setting powder is removed accidentally, dust the edge of the blade with some toner. •...

  • Page 679: Re-Assembly

    Transfer Belt Unit 2. Remove the screws from the ends of the driver roller bracket at the front [A] and rear [B]. 3. While holding the belt assembly level, raise the drive roller [C] to collapse the unit and release tension on the belt.
  • Page 680 4. Replacement and Adjustment 2. Clean the surface and underside of the transfer belt with a blower brush. 3. When you position the new the transfer belt unit over the rollers, make sure that the belt is centered between the triangular marks on front and rear side of the unit.
  • Page 681 Transfer Belt Unit 4. Confirm that all harnesses are connected and securely fastened in their hook clamps. 5. After re-installing the transfer belt unit, turn the belt and confirm that the toner collection coil turns. 6. Raise and lower the belt with lever C1 to make sure that the belt raises and lowers smoothly.

  • Page 682: Transfer Power Pack

    4. Replacement and Adjustment Transfer Power Pack 1. Remove the transfer belt unit. page 674 2. Remove the transfer belt assembly. page 675 3. Disconnect ground wire and free its harness across the width of the unit. 4. Free the ground harness at the rear...
  • Page 683 Transfer Belt Unit 5. Free the terminal wire at the front. 6. Remove the top screw [A] of the solenoid bracket, and then loosen the two left screws [B]. (This allows you to free the front terminal harness below the bracket at [A].)
  • Page 684 4. Replacement and Adjustment 7. Free the front terminal wire from under the loosened solenoid bracket. 8. Free the rear current terminal wire [A] at the rear. 9. Disconnect the power pack [A], and then unfasten the right edge of the power pack [B].

  • Page 685: Re-Installation

    Transfer Belt Unit 10. Lift the right edge of the power, remove it, and then lay it on a flat, clean surface. Re-installation • The power pack must be locked correctly in place, and all the harnesses must be secured in their clamps.
  • Page 686 4. Replacement and Adjustment 3. Pass the ground terminal wire under the top arm of the solenoid bracket [A] and then tighten the bracket screws [B] on the left. 4. After you connect the ground wire, make sure the wire is below all the wire guides at the top.

  • Page 687: Discharge Plate

    Transfer Belt Unit Discharge Plate 1. Remove the transfer belt unit Transfer page 674 • It is not necessary to remove the transfer belt assembly. However, work carefully to avoid scratching the surface of the belt. 2. Remove the shoulder screw and spring [A]. 3.

  • Page 688: Important Sp Codes: Transfer Belt Unit

    4. Replacement and Adjustment Important SP Codes: Transfer Belt Unit Here is a list of SP codes related to testing and servicing the development unit. Item SP No. Function Transfer belt, resistance 2970 Displays the resistance of the surface of the transfer belt.
  • Page 689 Transfer Belt Unit Item SP No. Function Transfer current, adjusting 2301 Adjusts the current applied to the transfer belt during copying. Many selections are available for both the area of the belt where the current is applied, and the type of paper in used.

  • Page 690: Fusing Unit

    4. Replacement and Adjustment Fusing Unit • Switch off the machine, disconnect the plug from the power source, and then wait a few minutes to allow the fusing unit to cool before you remove it from the machine. Fusing Unit Removal •...

  • Page 691: Thermostats, Thermistor, Nc Sensor

    Fusing Unit 11. Close D3. 12. Disconnect the unit at [C]. • At [C] the D223/D224 has one clamp and two connectors ( x1, x2), and the D225 has two clamps and three connectors ( x2, x3). 13. Remove fusing unit [D]. •...

  • Page 692: End Thermistor (D223/D224)

    4. Replacement and Adjustment End Thermistor (D223/D224) 1. Remove the fusing unit. page 688 2. Remove harness cover [A]. 3. Remove upper cover [A].
  • Page 693 Fusing Unit 1. Raise metal harness clamp [A]. 2. Disconnect thermistor harness [B]. 3. Disconnect spring [A], and then disconnect first bracket [B].
  • Page 694 4. Replacement and Adjustment 4. Disconnect second bracket [A]. 5. Remove the bracket with thermistor attached. 6. Separate the thermistor and bracket.

  • Page 695: End Thermistor (D225)

    Fusing Unit End Thermistor (D225) 1. Open the front door. 2. Pull out the fusing unit until it stops. 3. Remove upper cover [A]. 4. At the rear, open metal clamp [A], and then disconnect end thermistor harness [B].
  • Page 696 4. Replacement and Adjustment 5. Disconnect spring [A]. 6. Remove bracket [B] with thermistor and harness attached. 7. Separate thermistor and bracket.

  • Page 697: Thermostats

    Fusing Unit Thermostats The D223/D224 has three thermostats, the D225 has only two thermostats. 1. Open the front door. 2. Pull out the fusing unit until it stops. 3. Remove upper cover [A]. D223/D224 1. Disconnect the thermostat bracket.
  • Page 698 4. Replacement and Adjustment 2. Lay the bracket on a flat, clean surface. 3. Separate the thermostats from the bracket. D225 1. Disconnect the thermostat bracket. 2. Lay the bracket on a flat, clean surface. 3. Separate the thermostats from the bracket.

  • Page 699: Reinstallation

    Fusing Unit • To prevent a fire, never attempt to reset a blown thermostat by manipulating the exposed edges of the black cover with a screwdriver, or by hitting it on a table. • A thermostat that has been reset manually could fail and cause a fire. •...

  • Page 700: Center Thermistor (Nc Sensor) (D223/D224)

    4. Replacement and Adjustment 2. Tighten the screw for the round lead [A] as tight as possible without damaging the screw or screw hole. 3. Check the harness. • The harness should be straight [A]. This is correct. • If the harness is not straight between [1], [2] as [B], this is incorrect. This could cause error SC542 or SC545.
  • Page 701 Fusing Unit 4. At the front, raise metal harness clamps [A]. 5. Disconnect thermistor harness [B]. 6. Disconnect center thermistor harness bracket [A].

  • Page 702: Center Thermistor (Nc Sensor) (D225)

    4. Replacement and Adjustment 7. Remove the bracket with thermistor attached, and then separate bracket and thermistor [A]. Center Thermistor (NC Sensor) (D225) 1. Remove fusing unit upper cover. 2. At the rear [A], free the NC sensor harness. 3. Disconnect harness [B].
  • Page 703 Fusing Unit 4. Free harness [A] on top of the fusing unit. 5. Disconnect NC sensor bracket [B]. 6. Remove bracket with NC sensor and harness attached. 7. Separate bracket and harness.

  • Page 704: Web Cleaning Roller

    4. Replacement and Adjustment Web Cleaning Roller Web Unit Disassembly • The web unit can be removed without removing the fusing unit from the machine. 1. Open the front door and pull out the fusing unit on its support rails. 2.

  • Page 705: Re-Assembly

    Fusing Unit 1. Rotate the upper cover [A], down slightly, and then remove it. Also remove the end cover [B] 2. Remove web shafts [A]. 3. Remove the web cleaning rollers from shaft driver pins [B]. 4. Remove web bushing [C]. 5.

  • Page 706: Web Unit Re-Assembly

    4. Replacement and Adjustment Web Unit Re-assembly 1. Insert the end of the web into the slot , and attach the cleaning roller [A] 2. Insert the drive pins [B] into the web shaft 3. After installing bushing [C], rotate the shaft right to lock it, then attach the lock screw 4.

  • Page 707: Web Motor, Web End Sensor

    Fusing Unit • Before you re-assemble the machine, make sure there is no slack in the web roll, and confirm that the web is below the feeler of the web end sensor. 7. Attach the upper cover. 8. After installing a new web roll, do SP1902-001 to reset the web count to zero. Web Motor, Web End Sensor 1.
  • Page 708 4. Replacement and Adjustment 3. Remove web motor [C] 4. Remove web motor/sensor mount [A]. 5. Disconnect web end sensor [B].

  • Page 709: Reinstallation

    Fusing Unit Reinstallation 1. Set the motor in its bracket with the red dot facing toward the front end of the fusing unit. 2. Make sure that the harness of the web driver motor is not pinched by the fusing inner cover Pressure Roller Cleaning Unit, Cleaning Rollers Pressure Roller Cleaning Unit 1.

  • Page 710: Pressure Roller Cleaning Roller (D223/D224)

    4. Replacement and Adjustment Pressure Roller Cleaning Roller (D223/D224) 1. Remove the pressure roller cleaning unit. page 707 2. Disconnect the springs [A] on each end of the roller shaft [B]. 3. Separate the roller and bracket.

  • Page 711: Pressure Roller Cleaning Roller (D225)

    Fusing Unit Pressure Roller Cleaning Roller (D225) 1. Remove the pressure roller cleaning unit. page 707 2. Remove a screw on one end of the roller. 3. Disconnect roller from its bracket. Re-assembly 1. When attaching the lower cover of the pressure roller cleaning roller, make sure that the tab engages with the groove.

  • Page 712: Fusing Lamps, Hot Roller, And Pressure Roller

    4. Replacement and Adjustment 2. If the bushings are noisy after replacement, lubricate them on both ends and the holes where the bushings are attached with Barrierta Grease S522R. Fusing Lamps, Hot Roller, and Pressure Roller • If you wish to remove the pressure roller only, without removing the hot roller and fusing lamps, please do not use this procedure.
  • Page 713 Fusing Unit 1. At the rear, open the metal clamp, and then disconnect the harnesses. 2. Remove top cover plate [A] of the drawer connector.
  • Page 714 4. Replacement and Adjustment 3. Disconnect bracket connector, and then remove screw. 4. Unhook and then remove bracket [A].
  • Page 715 Fusing Unit 5. Disconnect lamp harnesses [A] (Blue) and [B] (Green) from the back of the drawer connector. 6. Open the bracket and then pull it away from the fusing unit.
  • Page 716 4. Replacement and Adjustment 7. Remove lamp holder [A], and then slowly pull the lamps out of the fusing unit. 8. Disconnect the connector cover at the front.
  • Page 717 Fusing Unit 9. Disconnect the fusing lamps at the front. 10. Remove the fusing lamp holder from the front.
  • Page 718 4. Replacement and Adjustment 11. Slowly, remove the fusing lamps. Re-assembly Each fusing lamp is rated for a different voltage and must be re-installed at its original location. • The rear lamp connectors are color coded (White, Green, Blue). • The rear lamp bracket is embossed with the letters W, G, B show your where each lamp with its White, Green, or Blue connector should be installed.

  • Page 719: Fusing Lamps (X2) D225

    Fusing Unit Fusing Lamps (x2) D225 1. Remove the fusing unit Fusing Unit Removal 2. In order to disconnect the fusing lamps, you must first remove the terminal plate on the rear end of the fusing unit. 3. At the rear [A] open the metal clamps to free the harnesses and then remove the screw at the top of the bracket.
  • Page 720 4. Replacement and Adjustment 5. At the lower rear corner, disconnect the harness, and then remove the bracket screw. 6. Remove the cover plate.
  • Page 721 Fusing Unit 7. Fusing lamp harnesses are blocking removal of bracket [A] so push them aside [B]. 8. At the lower left, lift the bracket [A] and pull it away from the rear of the fusing unit.
  • Page 722 4. Replacement and Adjustment 9. Disconnect the fusing lamps. 10. Lay the terminal bracket aside on a flat, clean surface.
  • Page 723 Fusing Unit 11. Remove the rear fusing lamp holder. 12. At the front, remove the plate.
  • Page 724 4. Replacement and Adjustment 13. Disconnect two harnesses. 14. Remove front fusing holder. 15. Remove the two fusing lamps.

  • Page 725: Hot Roller, Pressure Roller

    Fusing Unit • Never touch the surface of a fusing lamp with bare hands. • The fusing lamps are fragile so handle them with care. Re-assembly Each fusing lamp is rated for a different voltage and must be re-installed at its original location. •...
  • Page 726 4. Replacement and Adjustment 5. Disconnect entrance guide plate [A]. 6. Remove pressure roller [B]. • The pressure roller and pressure roller bearing should always be replaced together. 7. Lubricate the inner and outer surfaces of the bushings with Barrierta S552R.

  • Page 727: Pressure Roller Only

    Fusing Unit • If the bushings are warm, allow them to cool before applying the Barrierta grease. Applying the grease while the bushings are hot could generate gas. Pressure Roller Only Do this procedure if you need to remove only the pressure roller. 1.

  • Page 728: Checking The Fusing Nip

    4. Replacement and Adjustment • The fusing lamps are fragile. Work carefully to avoid breaking them. • During assembly, handle the roller carefully to avoid scratching it on the bracket. • Make sure the tabs and grooves of the lower cover are engaged correctly before tightening the screw.

  • Page 729: Stripper Pawls

    Fusing Unit 3. Click the button in the upper right corner of the screen to switch from the SP Screen to the Copy Screen. 4. Make a copy and then measure the width of the nip. • The optimum width for the D223/D224 is 5.5±05 mm •...
  • Page 730 4. Replacement and Adjustment 4. Stripper pawl [A].

  • Page 731: Nip Band Width Adjustment

    Fusing Unit Nip Band Width Adjustment 1. After the machine is turned on, make an A4/LT LEF copy, then stop the machine while the paper is still in the fusing unit by switching the machine off. • This is easier with an OHP sheet. Use an OHP sheet if you have one available. 2.

  • Page 732: Fusing/Exit Motor

    4. Replacement and Adjustment [E] Fusing exit sensor Fusing/Exit Motor 1. Remove rear upper cover Rear Upper Cover 2. Open the IOB Bracket 3. The fusing/exit motor is behind the fusing/exit motor bracket.
  • Page 733 Fusing Unit 4. Disconnect the harnesses in front of the fusing/exit motor bracket.
  • Page 734 4. Replacement and Adjustment 5. Disconnect the bracket screws at the upper right [A] and lower right [B]. 6. Disconnect bracket screw at lower left [A], and then pull the bracket [B] away from the frame.
  • Page 735 Fusing Unit 7. Move the frame out from behind harnesses [A]. 8. Remove the freed frame [B]. 9. Free the harness at the upper right corner of the motor bracket [A].
  • Page 736 4. Replacement and Adjustment 10. Press down pulley arm [A] to release tension on the belt. 11. Disconnect drive belt [B] from pulleys. 12. Disconnect ground plate at top and bottom.
  • Page 737 Fusing Unit 13. Remove ground plate and drive belt. • The top arm of the ground plate bracket has the "U" cutout.
  • Page 738 4. Replacement and Adjustment 14. Disconnect motor: [A] Top [B] Lower right [C] Lower left 15. Remove the bracket with motor attached. 16. Lay the bracket and motor on a flat, clean surface. 17. Turn the bracket over. 18. Remove the screws, and then separate the bracket and motor.

  • Page 739: Fusing Exit Sensor, Exit Unit Entrance Sensors

    Fusing Unit Fusing Exit Sensor, Exit Unit Entrance Sensors 1. Open the front door and pull out the exit/inverter unit. 2. Disconnect fusing exit sensor bracket [A]. 3. Remove fusing exit sensor [B]. 4. Disconnect exit unit entrance sensor bracket [C]. 5.

  • Page 740: Turn Sensor

    4. Replacement and Adjustment Turn Sensor 1. Remove the fusing unit cover. page 688 2. The sensor is on the left front corner of the fusing unit tray. 3. Disconnect and free harnesses [A].
  • Page 741 Fusing Unit 4. Disconnect sensor bracket [B]. 5. Remove bracket with sensor attached, and then disconnect sensor. 6. Separate sensor from bracket.

  • Page 742: Fusing Pressure Release Sensor

    4. Replacement and Adjustment Fusing Pressure Release Sensor 1. Remove the fusing unit. page 688 2. Remove fusing pressure release sensor bracket [A] 3. Separate bracket and sensor.

  • Page 743: Fusing Pressure Motor

    Fusing Unit Fusing Pressure Motor 1. Remove the fusing unit. page 688 2. Remove fusing pressure motor cover [A]. 3. Remove fusing pressure motor [A].

  • Page 744: Temperature Sensor

    4. Replacement and Adjustment 4. Lay the motor on a flat, clean surface. Temperature Sensor 1. Open the front door. 2. Move the toner bottle holder to the right. 3. Remove the inner cover next to the power switch.
  • Page 745 Fusing Unit 4. Disconnect the sensor harness and sensor bracket. 5. Remove the sensor bracket with sensor attached. 6. Separate the sensor and bracket.

  • Page 746: Important Sp Codes: Fusing Unit

    4. Replacement and Adjustment Important SP Codes: Fusing Unit Here is a list of SP codes related to testing and servicing the fusing unit. Item SP No. Function Fusing idling on/off 1907 This SP switches pre-fusing idling on/off. Pre-fusing idling can be switched on and adjusted for heavier, thick paper to improve fusing.
  • Page 747 Fusing Unit Item SP No. Function Nip band measuring 1109-001 Open SP1109-001, set it to “1”. Click the button in the upper right corner of the screen to switch from the SP Screen to the Copy Screen. Make a copy. The sheet of paper will stop in the nip of the pressure roller and hot roller for the prescribed time, and then exit.

  • Page 748: Duplex Unit

    4. Replacement and Adjustment Duplex Unit Duplex Unit Removal 1. Open the front door and pull out the duplex unit. 2. Remove the slide rail roller on the left [A] and on the right [B]. 3. Lift out the duplex unit [C]. Re-installation To re-install the duplex unit' 1.

  • Page 749: Jogger Fence Adjustment

    Duplex Unit 3. Move the handle lock screw [C] from the right to the center. 4. Loosen the left lock screw [D], then adjust the position of the duplex unit. Jogger Fence Adjustment SP1008 Duplex Fence Adjustment Execute this SP to adjust the distance between the jogger fences. A smaller value shortens the distance.

  • Page 750: Duplex Inverter Motor

    4. Replacement and Adjustment There are three motors in the duplex unit. Duplex inverter motor Duplex Jogger motor Duplex Transport motor Duplex Inverter Motor 1. Open the front door, and then pull out the duplex unit. 2. Remove the duplex unit front cover. page 747 3.
  • Page 751 Duplex Unit 4. Unhook the motor bracket [A], and then remove the bracket with motor attached [B].
  • Page 752 4. Replacement and Adjustment 5. Remove screws at [A] and [B]. 6. Separate motor and bracket. Re-assembly 1. Reattach the timing belt to the smaller gear marked with the green dot.

  • Page 753: Duplex Jogger Motor

    Duplex Unit 2. After re-attaching the motor, turn the motor gears [A] manually, and confirm that all the gears on the right [B] are turning. Duplex Jogger Motor 1. Open the front door, and then pull out the duplex unit. 2.
  • Page 754 4. Replacement and Adjustment 5. Open clamp [A] at right rear of bracket. 6. Open clamp [B] on left side of bracket. 7. Disconnect transport motor [A] on the right. 8. Clear freed harnesses around jogger motor [B].
  • Page 755 Duplex Unit 9. Disconnect jogger motor bracket. 10. Remove bracket with motor attached.

  • Page 756: Duplex Transport Motor

    4. Replacement and Adjustment 11. Separate motor and bracket. Duplex Transport Motor 1. Open the front door, and then pull out the duplex unit. 2. Remove the duplex unit front cover. page 747 3. Disconnect motor.
  • Page 757 Duplex Unit 4. Disconnect motor bracket: [A] top, [B] lower right, [C] lower left. 5. Remove bracket [A] with motor attached. 6. Lay the bracket and motor [B] on a flat, clean surface.

  • Page 758: Duplex Sensors

    4. Replacement and Adjustment 7. Re-install and remove the motor with bracket attached. There is no need to separate motor and bracket. Duplex Sensors Jogger Fence HP Sensor 1. Disconnect duplex unit release lever [A]. 2. Remove jogger HP sensor [B].

  • Page 759: Duplex Entrance Sensor

    Duplex Unit Duplex Entrance Sensor 1. Disconnect bracket [A] 2. Remove duplex entrance sensor [B].

  • Page 760: Duplex Transport Sensor 3

    4. Replacement and Adjustment Duplex Transport Sensor 3 1. Disassemble right half of table [A]. • The front screw is a shoulder screw. 2. Remove screw [B] to release the sensor bracket below. 3. Remove transport sensor 3 [C]. Inverter Exit Sensor, Transport Sensors 1, 2 1.
  • Page 761 Duplex Unit 3. Disconnect jogger fences [A]. 4. Disassemble left half of table [B]. • The front screw is a shoulder screw. • To avoid breaking the tabs under the left edge of the table, pull the table to the right to disengage the tabs before you remove it.

  • Page 762: Duplex Jogger Belt Adjustment

    4. Replacement and Adjustment Duplex Jogger Belt Adjustment 1. Remove cross stay Inverter. (See previous section.) 2. Remove reverse trigger roller shaft Inverter. (See previous section.) 3. Remove the left half of the table and the jogger motor bracket. • Slip the one end of the belt around the gear below the jogger motor. •...

  • Page 763: Important Sp Codes: Duplex Unit

    Duplex Unit Important SP Codes: Duplex Unit Here is a list of SP codes related to testing and servicing the duplex unit. Item SP No. Function Duplex fence adjustment 1008 Adjusts the distance between the jogger fences in the duplexer. A smaller value shortens the distance. If the fences are too far apart, skewing may occur in the duplex tray.

  • Page 764: Paper Feed Units

    4. Replacement and Adjustment Paper Feed Units Paper Trays Tandem Tray 1. Open the front door. 2. Pull out the Tray 1 [A] completely to separate the left [B] and right [C] sides of the tandem tray. 3. Remove the left tandem tray [A] ( x 5).
  • Page 765 Paper Feed Units 4. Right tandem tray [A]. Re-assembly When re-installing the right tandem tray: 1. Make sure that the wheels [A] ride on the slide rail [B]. 2. Make sure that the tandem tray stopper [C] is set behind the stopper [D] on the frame.

  • Page 766: Universal Trays

    4. Replacement and Adjustment Universal Trays 1. Pull out Tray 2 or Tray 3 [A]. 2. Lift the tray [B] out of the drawer.

  • Page 767: Rear Fence Return Sensor

    Paper Feed Units Rear Fence Return Sensor 1. Turn off the machine. 2. Pull out Tray 1, the tandem feed tray. 3. Remove rear bottom plate [A]. 4. Remove return sensor [B]. Rear Fence HP Sensor 1. Turn the machine off. 2.

  • Page 768: Tandem Right Tray Paper Sensor

    4. Replacement and Adjustment Tandem Right Tray Paper Sensor 1. Turn off the machine. 2. Remove the right tandem tray page 762 3. Remove cover [A]. 4. Side fences [B].
  • Page 769 Paper Feed Units 5. Remove bottom plate [A] 6. Disconnect sensor [B]. 7. Remove sensor [C].

  • Page 770: Bottom Plate Lift Wire

    4. Replacement and Adjustment Bottom Plate Lift Wire Before replacing the rear bottom plate lift wire, remove the front bottom plate lift wire. The shaft must be removed to replace the lift wire of the bottom plate. 1. Remove Tray 1, tandem tray. page 762 2.

  • Page 771: Re-Assembly

    Paper Feed Units Re-assembly 1. Set positioning pin [A] in hole [B]. 2. Set projection [C] in hole [D]. 3. Position wire [E] as shown. • Do not cross the wires.

  • Page 772: Tandem Tray Paper Size Change

    4. Replacement and Adjustment Tandem Tray Paper Size Change At the factory, this tray is set up for A4 or LT LEF. Only A4 or LT LEF paper can be used for tandem feed. 1. Open the front cover. 2. Pull out the Tray 1 [A] completely to separate the left [B] and right [C] sides of the tandem tray. 3.
  • Page 773 Paper Feed Units 5. Re-install the right tandem inner cover. 6. Remove tray cover [A]. 7. Remove the DC motor cover [B]. 8. Remove the rear side fence [A]. 9. Re-position rear cover [B].
  • Page 774 4. Replacement and Adjustment 10. Re-position the side fences [A], [B]. • A4: Outer slot position • LT: Inner slot position 11. Re-install the DC motor cover and tray cover. 12. Remove the rear bottom plate [A]. 13. Re-position the return position sensor bracket [B].

  • Page 775: Tandem Tray Side Registration

    Paper Feed Units • To use the paper tray for A4 size, set the screw in the left hole as shown. • For LT size, the screw should be placed on the right. 14. Reinstall the rear bottom plate. 15. Enter the new paper size with SP5959-001 (Paper Size – Tray 1). 16.

  • Page 776: Pick-Up, Feed, Separation Roller

    4. Replacement and Adjustment Pick-up, Feed, Separation Roller 1. Remove the tray. 2. Remove the clip for each roller to replace it. [1] Feed roller [2] Pick-up roller [3] Separation roller...

  • Page 777: Paper Tray Lift Motors, Tray 1 Lock Solenoids

    Paper Feed Units • The same FRR mechanism is used in all the trays, so the rollers are interchangeable between the trays. • Avoid touching the surface of new rollers during replacement. Paper Tray Lift Motors, Tray 1 Lock Solenoids Tray Motor, Solenoid Access 1.
  • Page 778 4. Replacement and Adjustment • While you are doing the procedures below, never touch any component on the PSU, especially a heat sink. • These heat sinks are live and labeled with warnings not to touch them. • These heat sinks can retain a considerable electrical charge for hours after the machine has been turned off and unplugged.
  • Page 779 Paper Feed Units 6. Pull the plate away from the corner of the machine. Do not remove it. 7. Disconnect all harnesses from the RYB, and then open the clamps above the RYB to free the harnesses. 8. Check the insulated harness on the right side of the RYB [A] and confirm that it is disconnected and free.
  • Page 780 4. Replacement and Adjustment 9. At the top of the AC drive board, open the clamp and free the large harnesses. 10. Near the left edge of the RYB, disconnect the harness guide bracket [A] by removing screws [1], [2], [3], and edge clamp [4]. 11.
  • Page 781 Paper Feed Units 12. Disconnect the mounting plate at on the left side of the RYB [1], on the right side of the RYB [2], and near the lower right corner of the AC drive board [3]. 13. Continue to disconnect the mounting plate near fan [1] and then fan [2]. 14.
  • Page 782 4. Replacement and Adjustment 15. With the mounting plate open, you can see the hidden components. Tray 1 Lift Motor Tray 2 Lift Motor Tray 3 Lift Motor Right Tray Lock Solenoid (in Tray 1) Left Tray Lock Solenoid (in Tray 1() •...

  • Page 783: Tray 1 Lift Motor

    Paper Feed Units Tray 1 Lift Motor 1. Open the board mounting plate. page 775 2. Disconnect the motor bracket. 3. Unhook the motor and remove it.

  • Page 784: Tray 2 Lift Motor

    4. Replacement and Adjustment Tray 2 Lift Motor 1. Open the board mounting plate. page 775 2. Disconnect the motor bracket. 3. Unhook the motor and remove it.

  • Page 785: Tray 3 Lift Motor

    Paper Feed Units Tray 3 Lift Motor 1. Open the board mounting plate. page 775 2. Disconnect the motor bracket. 3. Unhook the motor and remove it.

  • Page 786: Right Tray Lock Solenoid

    4. Replacement and Adjustment Right Tray Lock Solenoid 1. Open the board mounting plate. page 775 2. The right tray lock solenoid locks the right half of the tandem tray (Tray 1) during machine operation. It is located above Tray 2 lift motor [A]. 3.

  • Page 787: Left Tray Lock Solenoid

    Paper Feed Units 6. Disconnect the extension arm. 7. Disconnect and then remove the mounting plate. Left Tray Lock Solenoid 1. Open the board mounting plate. page 775 2. The left tray lock solenoid locks the left half of the tandem tray (Tray 1) during machine operation. It is located to the right of the right tray lock solenoid.
  • Page 788 4. Replacement and Adjustment 4. Lay the solenoid on a flat, clean surface, and then remove the extension arm. 5. Disconnect and then remove the mounting plate.

  • Page 789: Paper Feed Unit Removal

    Paper Feed Units Paper Feed Unit Removal There are three paper feed units, one for each tray. 1. Take off the front door. page 477 2. Remove the right covers. page 478 3. If the LCIT is connected, disconnect it and pull it away from the machine. 4.
  • Page 790 4. Replacement and Adjustment 7. Disconnect vertical cover [A]. 8. Pull it away slightly, and then disconnect the LED harness [B]. 9. At the rear, disconnect the fan harness at the rear right corner of the vertical transport guide plate.
  • Page 791 Paper Feed Units 10. Lift the vertical guide to disconnect it, and then pull it out of the machine. Tray 1 PFU • This procedure is for Tray 1 only. If you are servicing Tray 2 or Tray 3, just go to the next section below.
  • Page 792 4. Replacement and Adjustment 3. Disconnect the rear end of the machine, and then pull it out. Tray 1, 2, 3 PFU The remaining steps for PFU removal are basically the same for all PFUs. Each PFU has three connectors and one lock screw at the front.
  • Page 793 Paper Feed Units 3. Remove the lock screw. 4. Remove the PFU through the side of the machine. 5. Lay the PFU on a flat, clean surface.

  • Page 794: Paper Feed Motors

    4. Replacement and Adjustment Paper Feed Motors One paper feed motor is encased in each PFU unit. 1. Remove the feed unit, and then lay it on a flat, clean surface. Feed Unit Removal 2. Disconnect the corner bracket [A]. 3.
  • Page 795 Paper Feed Units • The lowest screw [1] is a machine screw. The other two screws are tapping screws. 4. Disconnect the motor. 5. Disconnect the motor cover plate at the front [A] and at the rear [B].
  • Page 796 4. Replacement and Adjustment 1. Remove the motor bracket [A] with motor attached. 2. Lay the motor and bracket [B] on a clean, flat surface. 3. Disconnect the bracket [A], and then separate motor and bracket [B]. 4. Disconnect the motor from the second bracket.

  • Page 797: Relay Motor

    Paper Feed Units 5. Remove the motor. Relay Motor 1. Take off the front door. page 477 2. Remove the right covers. page 478 3. If the LCIT is connected, disconnect it and pull it away from the machine. 4. Pull out all three trays completely but do not remove them. 5.
  • Page 798 4. Replacement and Adjustment 6. Open the vertical transport guide. 7. Disconnect vertical cover [A]. 8. Pull it away slightly, and then disconnect the LED harness [B].
  • Page 799 Paper Feed Units 9. At the rear, disconnect the fan harness at the rear right corner of the vertical transport guide plate. 10. Lift the vertical guide to disconnect it, and then pull it out of the machine.
  • Page 800 4. Replacement and Adjustment 11. Locate the relay motor unit [1] directly below PFU 1 [2]. 12. Disconnect the front end of the relay motor unit plate.
  • Page 801 Paper Feed Units 13. Remove the unit and lay it on a flat, clean surface. 14. Disconnect the motor from bracket [A]. 15. Disconnect motor [B]. 16. Connect the motor [A] before your re-attach it to the bracket with screws.

  • Page 802: Separation Roller Pressure Adjustment

    4. Replacement and Adjustment Separation Roller Pressure Adjustment The position of the drive gear for the separation roller can be changed to adjust the amount of pressure exerted by the separation roller. This adjustment can be done: • When feeding special paper (thick paper) •...

  • Page 803: Lift Sensor, Paper End Sensor

    Paper Feed Units 4. To adjust for thick paper, move the separation roller gear to the left to decrease the pressure. -or- To correct misfeeds, move the separation roller gear to the right to increase the pressure. Lift Sensor, Paper End Sensor 1.
  • Page 804 4. Replacement and Adjustment 5. Remove lift sensor, paper end sensor bracket [A] with sensors attached. 6. Remove lift sensor [A], paper end sensor [B] from the bracket.

  • Page 805: Feed Sensor, Vertical Transport Sensor

    Paper Feed Units Feed Sensor, Vertical Transport Sensor 1. Remove the PFU. page 787 2. Locate the feed sensor [A] and vertical transport sensor [B].
  • Page 806 4. Replacement and Adjustment 1. Open the two clamps on the back of the feed unit, free the harness, and then remove gear cover [A]. 2. Remove top cover [A] from the PFU. • The blue-circled screws in the photo are tapping screws.
  • Page 807 Paper Feed Units 3. Open clamp [A], free the harness, separate the top of the PFU, and then lay the separated parts on a flat, clean surface. • You do not need to disconnect the harness. 4. Remove feed sensor bracket [A]. 5.

  • Page 808: Pick-Up Solenoid

    4. Replacement and Adjustment 6. Remove vertical transport sensor [A]. Pick-up Solenoid 1. Remove the PFU. page 787 2. Remove the top cover of the PFU. 3. Locate the pick-up solenoid [A].
  • Page 809 Paper Feed Units 1. Disconnect springs [A], [B].
  • Page 810 4. Replacement and Adjustment • The longer spring [A] is the rear spring and must be re-attached at the same location. 2. At the rear end of the PFU, remove gear [A] and gear shaft [B].
  • Page 811 Paper Feed Units 3. Remove feed roller [A] and feed roller collar [B]. 4. Remove feed roller shaft assembly [A]. 5. Turn the PFU 90 degrees, and then remove solenoid screws at the back.
  • Page 812 4. Replacement and Adjustment 6. Remove spring [A], and then disconnect the harness. 7. Remove pick-up solenoid [A] at its back end, pull out the plunger, and then remove the solenoid. 8. Disconnect the plunger at each arm [A].

  • Page 813: Reverse Release Solenoid

    Paper Feed Units 9. Lay the parts on a flat, clean surface. Re-assembly 1. Make sure that the connector is inside sheet [A] so it cannot interfere with other parts. Reverse Release Solenoid 1. Remove the PFU. page 787 2. Remove the top cover of the PFU. 3.
  • Page 814 4. Replacement and Adjustment 4. Remove lift sensor, paper end sensor bracket. 1. Remove gear cover [A] from the rear end of the PFU. 2. Remove timing belt [A]. 3. Push in coupling [A] to detach the e-ring, and then remove the coupling.
  • Page 815 Paper Feed Units 4. Use a small, precision screwdriver to release the tab, and then remove coupling [A] to the outside. 5. Remove gears [A], [B], [C]. 6. Remove gears [A], [B], [C], [D].
  • Page 816 4. Replacement and Adjustment 7. Remove bracket [A]. 8. Disconnect reverse release solenoid bracket [A] and then remove it with solenoid attached. 9. Remove reverse release solenoid [A] from the bracket.

  • Page 817: Relay Sensor

    Paper Feed Units Relay Sensor 1. Remove the right upper cover. Right Upper Cover. 2. Disconnect relay sensor bracket [A]. 3. Remove relay sensor [B].

  • Page 818: Registration Motor

    4. Replacement and Adjustment Registration Motor 1. Remove the rear upper and lower covers. page 482 2. Remove the controller box. page 490 3. Remove the flywheel. 4. Disconnect the motor and motor bracket.
  • Page 819 Paper Feed Units • The bracket screws to be removed have hex-heads, not round heads. 5. Unhook the bracket with motor attached, and then lay it on a flat, clean surface. 6. Disconnect motor bracket [A]. 7. Raise the bracket and motor [B], and then disconnect the drive belt.
  • Page 820 4. Replacement and Adjustment 8. Disconnect the motor. 9. Separate motor and bracket.

  • Page 821: By-Pass Tray

    Paper Feed Units By-Pass Tray By-Pass Tray Removal The by-pass paper size detection board and paper length sensor (photosensor) are inside the by-pass tray. 1. Remove the bypass tray cover. 2. Disconnect the ground wire.
  • Page 822 4. Replacement and Adjustment 3. Free the harnesses at [A] and [B]. 4. Disconnect the bypass tray on the front side [A]. 5. Disconnect the tray on the rear side [B], and then remove the tray. 6. Lay the removed tray on a flat, clean surface.

  • Page 823: By-Pass Tray Disassembly

    Paper Feed Units 7. When you re-install the tray, tuck the harnesses into the corner slot of the bypass tray before you re-install it. By-Pass Tray Disassembly 1. Remove the By-Pass Tray. By-Pass Tray Removal 2. Disconnect the two halves of the tray.

  • Page 824: By-Pass Paper Size Detection Board

    4. Replacement and Adjustment 3. Push the top away from the bottom to separate the two halves of the tray. 4. Separate the top and bottom of the tray. By-Pass Paper Size Detection Board 1. Remove the By-Pass Tray. page 819 2.
  • Page 825 Paper Feed Units 4. Disconnect the paper size detection board 5. Carefully, detach the board from the tray. 6. Lay the board on a flat, clean surface.

  • Page 826: Re-Assembly

    4. Replacement and Adjustment Re-assembly Go into the SP mode and do SP1904 to calibrate the maximum and minimum paper sizes for the side fences: 1. SP1904-001 By-pass Tray Paper Size Detection – Minimum Size: Move the side fences to the minimum size, then execute this SP.
  • Page 827 Paper Feed Units 5. Disassemble the tray extension. 6. Free the sensor harness. 7. Turn the tray over, and then remove sensor cover [A]. 8. Disconnect the sensor hooks [B].
  • Page 828 4. Replacement and Adjustment 9. Disconnect sensor. Re-assembly 1. Before you re-assemble the tray extension, make sure that he sensor harness is fixed securely at the notches.

  • Page 829: By-Pass Tray Rollers

    Paper Feed Units By-Pass Tray Rollers 1. Remove right covers. page 478 2. Remove the By-Pass Tray page 819 3. Disconnect the by-pass cover [A] 4. Remove the by-pass cover. 5. With the cover removed, you can access the rollers.

  • Page 830: By-Pass Separation Roller Pressure Adjustment

    4. Replacement and Adjustment Pick-up roller Feed roller Separation (reverse) roller 6. Remove each roller and replace it. • During replacement, try to avoid touching the surfaces of the rollers with bare hands. • The FRR mechanisms for Tray 1 (tandem tray), Tray 2, Tray 3 (universal trays), By-Pass Tray, and ADF are similar, but the rollers are interchangeable only between Trays 1,2,3 (not By- Pass, ADF).

  • Page 831: Registration Sensor

    Paper Feed Units • When feeding special paper, especially thick paper • When the customer experiences feed problems 1. Use an Allen key to loosen the separation roller gear [A]. • The separation roller gear is positioned at the groove before shipping. 2.
  • Page 832 4. Replacement and Adjustment 2. Remove these components' • Development unit page 623 • Charge corona unit page 574 • OPC drum unit page 582 3. Remove paper dust collection unit [A] ( x 1, x 1)
  • Page 833 Paper Feed Units 4. Separate the unit. 5. Turn the top over and note the position of the mylar over the registration sensor. The mylar must remain on top of the sensor as shown.
  • Page 834 4. Replacement and Adjustment 6. Disconnect sensor and harness from the unit. 7. Disconnect sensor.

  • Page 835: By-Pass Unit

    Paper Feed Units By-Pass Unit By-Pass Unit Removal • Work carefully to avoid catching any harnesses on the unit while removing and re-installing it. Preparation • Remove the front door. page 477 • Remove the development unit. page 623 • Remove by-pass tray. page 819 •...
  • Page 836 4. Replacement and Adjustment 3. Disconnect the harnesses at the front right corner. 4. Note the color sequence of the connectors at [A] ([1] Blue, [2] Black, [3] White). 5. At the right front corner, pull the harnesses [A] through the frame so they will not block removal of the bypass unit.
  • Page 837 Paper Feed Units 6. At the right rear corner [A], disconnect the large connectors. 7. Below the position where you just removed the large connectors, remove the two harnesses with the small connectors [B]. 8. Pull the loose harnesses away from rear corner of the machine so they cannot interfere with removal of the bypass unit.
  • Page 838 4. Replacement and Adjustment 9. The used toner pump tube assembly and drive rod [A] block the access to the bypass unit motor and sensor connectors [B]. 10. Disconnect top of used toner pump assembly [A]. 11. Pull out the stopper on the tube base [A].
  • Page 839 Paper Feed Units 12. Pull the bottom of the tube [A] up, and then remove the tube pump assembly [B]. 13. Disconnect the bypass motor and sensors. 14. On the right side of the machine, disconnect the frame of the bypass unit.
  • Page 840 4. Replacement and Adjustment 15. Pull the duplex unit [A] out of the machine far enough so you can see the pin [B] disengage from the frame of the duplex unit (about 10 cm or 4 in.) • If the duplex unit remains closed, you cannot remove or re-install the bypass unit. The duplex unit must be pulled out so the pin is free before you can remove the unit or re-install it.

  • Page 841: Re-Installation

    Paper Feed Units 18. Set the unit on a flat, clean surface. Re-installation 1. Pull out the duplex unit [A] before you re-install the bypass unit, and then confirm that pin [B] is out of its hole. • If the duplex unit is in the machine, you will not be able to re-install the bypass unit. Make sure the duplex unit is pulled out completely.

  • Page 842: By-Pass Motor

    4. Replacement and Adjustment 2. After you have re-installed the bypass unit and re-connected the motor and sensors, check this sensor to the right and make sure that it is securely connected. 3. Work carefully to avoid catching any harnesses on the unit while moving it. 4.
  • Page 843 Paper Feed Units 3. Unfasten the motor bracket. 4. Loosen the tension screw to create some slack in the drive belt.
  • Page 844 4. Replacement and Adjustment 5. Remove the bracket with motor attached, and then disconnect the motor from the bracket. 6. Separate the motor and drive belt.

  • Page 845: Guide Plate Sensor

    Paper Feed Units 7. After you re-install the motor, move the tension screw to put more tension on the belt, and then tighten the screw. Guide Plate Sensor 1. Remove the by-pass unit. By-pass Unit Removal 2. The guide plate sensor is on the inside of the rear plate.
  • Page 846 4. Replacement and Adjustment 3. On the other side of the plate, raise the guide plate away from the sensor. 4. Free the harness [A]. 5. Unfasten the sensor [B]. 6. Disconnect sensor and harness.

  • Page 847: Paper Path Leds

    Paper Feed Units Paper Path LEDs LED Locations The paper feed path LEDs are mounted inside the inner covers on the front of the main machine. An LED lights when a paper jam occurs at that location. Name Jam LED A Jam LED B1 Jam LED B2...

  • Page 848: Jam Led A: Vertical Inner Cover

    4. Replacement and Adjustment Name Jam LED C2 Jam LED C1 Jam LED D1/E1 Jam LED D2/D3 Jam LED E2/Z Each LED assembly is comprised of a plate held by one screw [1], an easily detachable lens [2], a small harness and connector [3] and the LED [4].
  • Page 849 Paper Feed Units 5. Lay the inner cover on a flat, clean surface. 6. Remove plate [1], remove LED and lens, and then disconnect the LED [2]. 7. Separate the LED and lens [3].

  • Page 850: Jam Led C1 Inner Cover

    4. Replacement and Adjustment Jam LEDs C2, B2, B1 1. Open the front door. 2. Disconnect the inner cover [A]. 3. Pull the cover away slightly, and then disconnect harness [B]. 4. Lay the inner cover on a flat, clean surface. 5.

  • Page 851: Jam Led E3/Z: Inverter Duplex Inner Cover

    Paper Feed Units 4. Lay the inner cover on a flat, clean surface. 5. Remove plate, and then disconnect the LED [1]. 6. Separate the LED and lens [2]. Jam LED E3/Z: Inverter Duplex Inner Cover 1. Open the front door. 2.

  • Page 852: Jam Led D1/E1: Fusing Unit Inner Cover

    4. Replacement and Adjustment 5. Lay the duplex unit front cover on a flat, clean surface. 6. Remove plate, and then disconnect the LED [1]. 7. Separate the LED and lens [2]. Jam LED D1/E1: Fusing Unit Inner Cover 1. Open the front door. 2.
  • Page 853 Paper Feed Units 4. Locate the hole [A] in the shaft of the large knob on the front of the fusing unit. 5. If you cannot see the hole, turn the knob until the hole is visible. 6. Insert a small screwdriver [B] into hole to keep the shaft from turning when you remove the large knob.
  • Page 854 4. Replacement and Adjustment 9. Disconnect right side [A] and left side [B] of the cover. 10. Pull the cover away slightly, and then disconnect harness [A].
  • Page 855 Paper Feed Units 11. Lay the cover on a flat, clean surface. 12. Remove plate [1]. 13. Disconnect the LED, and then separate the LED and lens [2]. 14. Remove plate [1]. 15. Disconnect the LED, and then separate the LED and lens [2].

  • Page 856: Paper Feed Adjustments

    4. Replacement and Adjustment Re-assembly 1. Be sure to remove the screwdriver and close the top of the fusing unit before you push the fusing unit into the machine. Paper Feed Adjustments Paper Registration The position of image on paper can be adjusted with SP codes in the main scan and sub scan directions. Before doing any of these adjustments you should always first check the alignment of the laser unit.

  • Page 857: Buckle Adjustment

    Paper Feed Units • SP1002-001 to 007 (Side-to-Side Registration). Use this SP code to correct paper registration problems for each paper feed station (Tray 1, Tray 2, Tray 3, Bypass Tray, LCIT, and Duplex Tray (during duplex printing). These settings correct printing position. •...

  • Page 858: Important Sp Codes: Paper Feed

    4. Replacement and Adjustment 1003 Registration Buckle Adjustment 3 By-pass Tray 4 Thick Paper Tray 5 Thick Paper Duplex Tray Important SP Codes: Paper Feed Here is a list of SP codes related to testing and servicing paper feed components. Item SP No.
  • Page 859 Paper Feed Units Item SP No. Function Registration, sub scan 4010 Adjusts the registration of the leading edge for scanning in the sub scan direction.

  • Page 860: Pcbs, Hdd

    4. Replacement and Adjustment PCBs, HDD Before You Begin Board Locations The number of boards has been reduced for the machines of this series. These boards have been eliminated: • IPU (Functions moved to the BICU) • CTL PSU (Controller PSU) •...
  • Page 861 PCBs, HDD Below the Controller Box AC drive board Behind the Controller Box The controller box must be opened to access this board.

  • Page 862: Controller Board Replacement

    4. Replacement and Adjustment • Before you touch a board, touch a metal surface to discharge accumulated static from your hands. • Remove screws carefully so the tip of the screwdriver does not touch any part of the board. • Handle boards carefully by their edges to avoid sharp edges and points on the backs of the boards.

  • Page 863: Controller Board

    PCBs, HDD Controller Board 1. Remove the rear upper cover. page 482 2. Remove controller box cover plate. page 488 3. If there are any option I/F boards in the controller box remove them. 4. Disconnect the bottom of the controller board.
  • Page 864 4. Replacement and Adjustment 5. Unfasten board from the machine. 6. Unfasten the controller faceplate.
  • Page 865 PCBs, HDD 7. Slowly, with one hand on the board and one hand on the faceplate, disconnect the edge connector on the left, remove the board and faceplate together, and then lay them on a flat, clean surface. 8. Remove the port cover [A] of the USB-B port from the controller board guide plate.
  • Page 866 4. Replacement and Adjustment 9. Separate the controller board and controller board guide plate. 10. Remove both NVRAMs from the old controller board and install them on the new controller board.
  • Page 867 PCBs, HDD • The controller board has two NVRAMs, 2M-1 and 2M-2. • These NVRAMs are always replaced as a set. • Each NVRAM must be installed at the correct location as shown above. • If their positions are reversed, this will cause a short circuit and damage the board and NVRAMs.

  • Page 868: Controller Board Nvram

    4. Replacement and Adjustment Controller Board NVRAM 1. Locate the SMC printout from the factory provided with the main machine. 2. Do SP5990-001 (All – Data List) to print out all the current machine settings. 3. Turn the machine off. 4.
  • Page 869 PCBs, HDD • Special Destination List: Fax Initial Setting > Receive Setting > Special Destination Setting: List Print > Print • Fax Initial Setting >Receive Settings > Onscreen items and settings • Fax Initial Setting > Send Settings > Onscreen items and settings 11.
  • Page 870 4. Replacement and Adjustment • Wait for the message that tells you the download has finished and to cycle the machine off/on, but do not turn the machine off. Touch the Close button. • If the machine issues SC870-11 (Address Book Data Error), just ignore this message and continue with this procedure.

  • Page 871: Hdd Removal

    PCBs, HDD HDD Removal 1. Remove the rear upper cover. Rear Upper Cover 2. Remove controller box cover plate. Controller Box Cover Plate 3. The single HDD (320 MB) is located below the controller board [A] on the right. 4. Disconnect the HDD from the controller board. 5.
  • Page 872 4. Replacement and Adjustment 6. Unhook the HDD bracket from the machine frame. 7. Lay the bracket with HDD attached on a flat, clean surface.

  • Page 873: Re-Installation

    PCBs, HDD 8. Remove the screws from the bracket front [A] and rear [B]. 9. Separate the HDD from the bracket. Re-installation 1. Hook the HDD bracket to the frame on the right so the bracket is flat against the frame.

  • Page 874: After Hdd Replacement

    4. Replacement and Adjustment • If the bracket is not flat against the frame you will not be able to re-attach the screws. 2. After restoring the machine for normal operation, execute SP5832-011 (HDD Format – All) to format the hard disk. After HDD Replacement Explain to the operator that after a faulty HDD has been replaced the following data is lost and cannot be recovered'...
  • Page 875 PCBs, HDD 1. Remove the rear upper cover. page 482 2. Remove controller box cover plate. page 488 3. Disconnect the top right corner [A] and bottom right corner [B] of the BICU. 4. Disconnect the top right corner [A] and left side [B] of the BICU.
  • Page 876 4. Replacement and Adjustment 5. Unfasten the board from the machine frame, and the slowly pull the board to the left to remove it.
  • Page 877 PCBs, HDD 6. Remove the NVRAM from the old BICU and install it on the new BICU.
  • Page 878 4. Replacement and Adjustment 7. Connect the right edge of the BICU to the left edge of the controller board [A]. 8. Re-install the rear covers, and then turn the machine on.

  • Page 879: Bicu Nvram

    PCBs, HDD 9. Open SP5811-004, and then enter the BICU number (displayed at SP5811-005). 10. Cycle the machine off/on. 11. Do the SP/UP settings as needed. 12. Cycle the machine off/on again to execute the initial process control cycle. BICU NVRAM 1.

  • Page 880: Ryb (Relay Board)

    4. Replacement and Adjustment 10. Connect the machine to its power source, and then turn the machine on. 11. Open SP5131, and then select your location. 12. Enter the ID number for the new NVRAM. • This is not the same number entered for the NVRAM with SP5811-04 (Machine Serial Number Set –...
  • Page 881 PCBs, HDD 5. Unfasten the top edge of the board. 6. Unfasten the bottom edge of the board. 7. Remove the board.
  • Page 882 4. Replacement and Adjustment 8. Lay the board on a flat, clean surface. 9. When you re-install the board, carefully check around the edges to make sure that there are no connectors or harnesses caught below the board. • Work carefully around the PSU. •...
  • Page 883 PCBs, HDD • The heat sinks [A] are live and labeled with warnings not to touch them. • A heat sink can retain a considerable electrical charge for hours, even after the machine has been turned off. 1. Remove both rear covers. Rear covers. 2.
  • Page 884 4. Replacement and Adjustment 5. Unfasten the left side and right side of the PSU. • Handle the PSU carefully by its edges. • Never touch any component on the PSU with your hand or a tool, especially one of the heat sinks.
  • Page 885 PCBs, HDD • To avoid personal injury, never touch the back of the board. • Some of the soldered contacts are extremely sharp and can cut or puncture your fingers if you grip the back of the board. 6. While carefully handling the board by its edges, lay the PSU on a flat clean surface. 7.
  • Page 886 4. Replacement and Adjustment 1. Remove both rear covers. Rear covers. 2. Open the controller box. Controller Box 3. The DHB is the small board below the vertical AC drive board on the right. 4. Disconnect the three visible connectors [A]. 5.

  • Page 887: Ac Drive Board

    PCBs, HDD 6. Unfasten the board, and then remove it. 7. Lay the DHB on a flat, clean surface. AC Drive Board 1. Remove both rear covers. Rear covers. 2. Open the controller box. Controller Box 3. The AC drive board is the large vertical board on the right.
  • Page 888 4. Replacement and Adjustment 4. Disconnect the board. 5. Unfasten the top of the board.
  • Page 889 PCBs, HDD 6. Unfasten the left side of the board [A] and the right side of the board [B]. 7. Slowly, work the board out from behind the large harnesses, and then remove it.
  • Page 890 4. Replacement and Adjustment 8. Lay the board on a flat, clean surface. 9. Note the position of fuses FU101, FU102. 10. Obey the warning to replace these fuses with fuses of the same type and rating.
  • Page 891 PCBs, HDD 11. The bayonet connectors at the lower left corner of the board must be installed with the black connector on the left and white connector on the right. 12. The connector blades are clearly marked "BLACK" and "WHITE" to indicate the correct connection point.
  • Page 892 4. Replacement and Adjustment 1. Remove the rear upper cover. Rear upper cover 2. Open the controller box. Controller Box 3. The IOB is on the back of the main machine. 4. Disconnect the top edge of the board.
  • Page 893 PCBs, HDD 5. Disconnect the right edge of the board. 6. Allow the harness bundle to hang down as shown. 7. Disconnect the bottom edge of the board. 8. Disconnect the left edge of the board.
  • Page 894 4. Replacement and Adjustment 9. Unfasten the board from the frame, and then remove it.

  • Page 895: Important Sp Codes: Pcbs, Hdd

    PCBs, HDD 10. Lay the board on a flat clean surface. Important SP Codes: PCBs, HDD Here is a list of SP codes related to testing and servicing the main boards and the HDD. Item SP No. Function Data Overwrite Security: Enable 5878-1 Enables the Data Overwrite Security feature.
  • Page 896 4. Replacement and Adjustment Item SP No. Function HDD encryption 5878-2 Enables the HDD encryption feature. NVRAM data download 5825 Downloads data from an SD card to the NVRAM in the machine. After downloading is completed, remove the SD card and cycle the machine off/on. NVRAM data upload 5824 Uploads the UP and SP mode data (except...

  • Page 897: Adf Removal

    ADF Removal 1. Remove the rear upper cover. page 482 2. Remove the controller box cover. page 488 3. Disconnect cable brackets [A] and [B]. 4. Disconnect ground wire [C]. 5. Pull away both brackets with harnesses connected. 6. Free harnesses [A] and [B] on top of the controller box. 7.
  • Page 898 4. Replacement and Adjustment 8. Disconnect the cable inside the controller box. 9. Remove the screws on the ADF base on the left and right.
  • Page 899 10. Slowly and carefully (the ADF is heavy) lift the ADF [A] off the machine. 11. Set the ADF on its edge on the floor, and then lean it against a wall [B]. • To prevent damage to the fragile feelers [A] of the ADF position sensor, never lay the ADF on a flat surface as shown below.

  • Page 900: After Adf Replacement

    4. Replacement and Adjustment • If the ADF is being replaced, do SP4-730-002 after the new ADF has been installed. After ADF Replacement CIS RGB Adjustment 1. The correct RGB settings for the ADF are listed in the specifications sheet that comes with the machine.

  • Page 901: Checking The Horizontal Registration

    The large arrow indicates the direction of feed. 2. Copy the original and make sure that the position of the line [A] is within 0±1mm 3. If not within the standard, adjust with the SP modes. Checking the horizontal registration SP6-006-010 (ADF Adjustment L-Edge Regist (1-Pass): Front) SP6-006-011 (ADF Adjustment L-Edge Regist (1-Pass): Rear) 1.

  • Page 902: Checking Magnification

    4. Replacement and Adjustment Checking magnification SP6-017-001 (DF Magnification Adj.) 1. Copy the original and make sure that the length of the line [B] is within 100±1mm. 2. If not within the standard, adjust with the SP mode. Platen Adjustment 1.

  • Page 903: Adf Covers

    3. Close the ADF [A] slowly and paste the ADF and the white cover [B] with the magic tapes. ADF Covers ADF Front Cover page 901 1. Open the feed cover [A].
  • Page 904 4. Replacement and Adjustment 2. Slide the ADF front cover [A] to the left. • Check the position of the hooks in the photo below before removing.

  • Page 905: Adf Rear Cover

    ADF Rear Cover 1. Open the feed cover [A]. 2. Cover [A]. 3. Lift off the rear cover [A].

  • Page 906: Feed Cover

    4. Replacement and Adjustment • Check the position of the hooks before removing. Feed Cover 1. ADF front cover ADF page 901 2. ADF rear cover ADF page 903 3. Feed cover [A].

  • Page 907: Original Feed Unit

    Original Feed Unit 1. Open the feed cover. 2. Remove the snap-fit [A]. 3. Original feed unit [A] (Pull the original feed unit, remove the back side of the shaft. Then, remove the bushing in the foreground.)

  • Page 908: Pick-Up Roller, Transport Belt

    4. Replacement and Adjustment Pick-up Roller, Transport Belt 1. Remove original feed unit. page 905 2. Slide bushing [A], and then remove the pick-up roller unit [B]. • At re-assembly, make sure that the tab on the front guide plate [A] is above the pick-up roller [B].
  • Page 909 3. Pick-up roller cover [A] and pick-up roller [B]. 4. Lift the left and right sides of the feed belt holder [A], then remove it. 5. Remove the feed belt [B] from the feed belt holder [A].

  • Page 910: Adf Separation Roller

    4. Replacement and Adjustment ADF Separation Roller 1. Open the feed cover. 2. Original feed unit page 905 3. ADF separation roller cover [A]. 4. ADF separation roller [A] and torque limiter clutch [B] (snaps off)

  • Page 911: Original Registration Sensor

    Original Registration Sensor 1. Entrance lower guide [A]. 2. Scanning guide plate [A]. 3. Original registration sensor [A] along with the bracket.

  • Page 912: Original Exit Sensor

    4. Replacement and Adjustment 4. Original Registration Sensor [A]. Original Exit Sensor 1. Entrance lower guide [A].
  • Page 913 2. Scanning guide plate [A]. 3. Open the white cover [A]. 4. Remove the original exit sensor [B], which is mounted on the upper guide [A].

  • Page 914: Adf Control Board

    4. Replacement and Adjustment 5. Remove the original exit sensor [B] from the upper guide [A]. ADF Control Board 1. ADF rear cover ADF page 903 2. ADF control board [A].

  • Page 915: Separation Sensor, Skew Correction Sensor

    Separation Sensor, Skew Correction Sensor 1. Feed upper guide [A] in the feed cover. 2. Remove the sensors along with the bracket [A].

  • Page 916: Original Width Sensor, Interval Sensor

    4. Replacement and Adjustment 3. Separation Sensor [A] and Skew Correction Sensor [B]. Original Width Sensor, Interval Sensor 1. Feed cover Feed Cover 2. Guide plate [A].

  • Page 917: Original Length Sensors

    3. Interval sensor [A]. 4. Remove the original width sensor guide plate [A]. 5. Remove the five original width sensors [B]. Original Length Sensors 1. Raise the document tray [A], then remove the lower cover [B].

  • Page 918: Aps Feeler

    4. Replacement and Adjustment 2. Original Length Sensors [A] B5 [B] A4 [C] LG APS Feeler 1. ADF rear cover ADF page 903 2. APS Feeler [A].

  • Page 919: Adf Lift Interlock Switch, Lift Sensor

    ADF Lift Interlock Switch, Lift Sensor 1. ADF Control Board page 912 2. ADF lift-up interlock SW [A] along with the bracket ( x 3, x 2) 3. Lift-Up Sensor [A] along with the bracket.

  • Page 920: Original Set Sensor

    4. Replacement and Adjustment Original Set Sensor 1. ADF front cover page 901 2. Remove the screw and raise the original tray [A]. 3. Original set sensor [A].

  • Page 921: A4 Lef, Lt Lef Sensor

    A4 LEF, LT LEF Sensor 1. ADF front cover page 901 2. Remove the screw and raise the original tray [A]. 3. A4 LEF/LT LEF Sensor [A]. Bottom Plate HP Sensor 1. Original feed unit page 905 2. ADF front cover page 901 3.

  • Page 922: Bottom Plate Position Sensor

    4. Replacement and Adjustment 4. Bottom plate HP sensor [A]. Bottom Plate Position Sensor 1. ADF rear cover page 903 2. Original feed unit page 905 3. Bottom plate position sensor [A].

  • Page 923: Adf Feed Cover Interlock Sw, Pick-Up Roller Hp Sensor

    ADF Feed Cover Interlock SW, Pick-up Roller HP Sensor 1. ADF rear cover page 903 2. Remove the ADF feed cover interlock SW [A] from the retaining bracket. 3. ADF feed cover interlock SW [A]. 4. Pick-up roller HP sensor [A] along with the bracket.

  • Page 924: Adf Entrance Motor

    4. Replacement and Adjustment ADF Entrance Motor 1. ADF rear cover page 903 2. ADF entrance motor [A] along with the frame. 3. ADF entrance motor [A].

  • Page 925: Adf Scanning Motor

    ADF Scanning Motor 1. ADF entrance motor along with the frame page 922 2. ADF scanning motor [A] along with the bracket. 3. ADF scanning motor [A].

  • Page 926: Adf Exit Motor

    4. Replacement and Adjustment ADF Exit Motor 1. Remove the rear cover. page 903 2. The exit motor is on the back of the machine behind the vertical stay. 3. Remove the ADF control board. 4. Remove the anti-static plate.
  • Page 927 5. Unfasten the motor. 6. Disconnect the drive belt.

  • Page 928: Adf Bottom Plate Lift Motor

    4. Replacement and Adjustment 7. Disconnect the motor and remove it. ADF Bottom Plate Lift Motor 1. ADF entrance motor along with the frame page 922 2. ADF bottom plate lift motor [A]. ADF Pick-up Roller Lift Motor, ADF Transport Motor 1.
  • Page 929 3. ADF pick-up roller lift motor [A]. 4. ADF transport motor [A] along with the bracket.

  • Page 930: Adf Feed Motor

    4. Replacement and Adjustment 5. ADF transport motor [A]. ADF Feed Motor 1. ADF rear cover page 903 2. Remove the fixing screws of the frame (black) [A].
  • Page 931 3. ADF entrance motor along with the frame ADF Entrance Motor 4. ADF feed motor [A] along with the bracket. 5. ADF feed motor [A].

  • Page 932: Cis Unit

    4. Replacement and Adjustment CIS Unit 1. Original Feed Unit page 905 2. ADF Separation Roller page 908 3. ADF front cover page 901 4. Raise the ADF. 5. Push the P release to the left to release white plate [A]. This will prevent scratching the CIS glass when the unit is removed.
  • Page 933 7. Guide plate (small) [A]. 8. Unfasten guide plate [A]. 9. Remove guide plate with mylar [B] attached. 10. At the front, disconnect timing belt. 11. Unfasten mylar plate and then remove it.
  • Page 934 4. Replacement and Adjustment 12. Disconnect CIS unit [A]. 13. Slowly, pull the CIS unit [B] out of the ADF. 14. Lay the CIS unit on a flat, clean surface, with the glass side facing up. Reinstallation 1. Before reinstallation, clean the surface of the CIS lens with a lens cloth. •...
  • Page 935 3. To re-install the CIS, set the CIS in its channel so it is perfectly flat. 4. Slowly, push it to the rear until the pegs slide into the holes. 5. Follow the correct arrangement of the drive belt when you re-attach it. 6.

  • Page 936: Cis White Roller Cleaning

    4. Replacement and Adjustment • SP4-730-002 CIS White Roller Cleaning Frequently inspect the CIS white roller. A dirty or incorrectly installed white roller will cause the machine to issue SC152-00 (White Level Error: Back Side). 1. Open the ADF. 2. At the upper left corner, release the white plate. 3.

  • Page 937: Important Sp Codes: Adf

    Important SP Codes: ADF Here is a list of SP codes related to testing and servicing the ADF. For more details about procedures to be done after ADF replacement, see "Adjustment after ADF Replacement" at the beginning of this section. After ADF Replacement Item SP No.
  • Page 938 4. Replacement and Adjustment • SP4-730-001 • SP4-730-004 • SP4-730-002...

  • Page 939: Fans, Switches

    Fans, Switches Fans, Switches Fans Quick Reference Here is a list of the fans described in this section and the corresponding SC code issued by the machine in case of a failure. SC Code SC530-01 Drum Fan* SC530-02 Development Unit Fan 1 SC530-02 Development Unit Fan 2 SC530-04...

  • Page 940: Drum Fan

    4. Replacement and Adjustment SC Code New fan for this machine. "Drum fan" in previous machine. Drum Fan 1. Remove rear upper cover. page 482 2. The drum fan is at the rear right corner of the machine above the flywheel. 3.
  • Page 941 Fans, Switches 5. Pull the duct with fan attached out of the machine. 6. Unfasten the fan, and then separate it from the duct bracket.

  • Page 942: Development Unit Fan 1, 2

    4. Replacement and Adjustment Development Unit Fan 1, 2 1. Remove the right upper cover. page 478 2. There are two development unit fans, Fan 1 [1] and Fan 2 [2]. 3. Disconnect the fan bracket. 4. Pull the bracket with fans attached out of the machine, and then lay it on a flat, clean surface.
  • Page 943 Fans, Switches 5. Disconnect the front of the fan cover [A] and rear of the fan cover [B]. 6. Remove the fan cover. Fan 1 1. Disconnect Fan 1 from the bracket.
  • Page 944 4. Replacement and Adjustment 2. Remove the fan from the bracket. Fan 2 1. Disconnect Fan 2 from bracket. 2. Remove the fan from the bracket.

  • Page 945: Duplex Fan

    Fans, Switches Duplex Fan 1. Remove front door. page 477 2. Remove Tray 1. page 762 3. Remove duplex unit. page 746 4. Remove left lower cover. page 487 5. Pull out fusing unit. 6. The duplex fan is in the center of the machine, below the duplex unit. 7.
  • Page 946 4. Replacement and Adjustment 8. From the front of the machine [A], disconnect the fan bracket. 9. From the left side of the machine, disconnect the fan bracket [A], and then remove the bracket with fan attached from the machine [B].
  • Page 947 Fans, Switches 10. Disconnect the plate. 11. Separate plate and fan. PCU Fan 1. Open the front door. 2. Swing open the toner bottle holder. 3. Disconnect inner cover C1.
  • Page 948 4. Replacement and Adjustment 4. Lower handle C1 [A]. 5. Remove cover [B], and then lay it on a flat, clean surface. 6. Disconnect and remove plastic cover [A]. 7. Slide the fan out of its bracket. There are no screws.

  • Page 949: Toner Bottle Fan

    Fans, Switches • The fan must be re-installed with the label side up. Toner Bottle Fan 1. Open the front door. 2. Remove inner cover [A]. 3. Duct [B] is the duct of the toner bottle fan inside the machine. 4.
  • Page 950 4. Replacement and Adjustment 6. Disconnect left side [A] of the laser unit cover. 7. Disconnect center of the cover [B]. 8. Disconnect front right corner of cover [A]. 9. Disconnect rear right corner of cover [B].
  • Page 951 Fans, Switches 10. Free harness [A] behind cover. 11. Pull cover [B] slightly to the rear. You do not need to remove the cover. 12. Disconnect the fan.
  • Page 952 4. Replacement and Adjustment 13. Release tab [A] on the left side of the duct. 14. Pull duct with fan attached [B] out of the machine. 15. Separate the fan and duct.
  • Page 953 Fans, Switches Re-installation 1. When you re-install the fan, first, set tab [A] into the slot on the right. 2. Next, set and lock tab [B] on the left. 3. Check the front of the machine. 4. Confirm that the fan duct is flat and parallel to the frame as shown.

  • Page 954: Fusing Inner Cover Fan

    4. Replacement and Adjustment 5. If the duct is not straight, set the fan again. Fusing Inner Cover Fan 1. Open the front door, and then pull out the fusing unit. 2. The fan is inside the cover at the upper right corner. 3.
  • Page 955 Fans, Switches 7. Disconnect the fusing unit cover. 8. Pull the cover slightly away, and then disconnect the LED harness. 9. Remove the cover and lay it on a flat, clean surface. 10. At [A] disconnect the fan and free the LED harness.
  • Page 956 4. Replacement and Adjustment 11. Unfasten the duct cover [B]. 12. Remove the duct with fan attached. 13. Unfasten the fan from the duct.
  • Page 957 Fans, Switches 14. Separate the fan from the duct. PSU Fan 1, 2 1. Remove the rear covers. page 482 2. Open the controller box. page 490 3. The PSU fans [1] and [2] are located directly below the PSU. •...
  • Page 958 4. Replacement and Adjustment • Always handle the PSU by its edges. 4. Remove the PSU. PSU Fan 1 1. PSU Fan 1 is on the left. 2. Disconnect and unfasten the fan, and then remove it.
  • Page 959 Fans, Switches 3. There is no fan bracket. PSU Fan 2 1. PSU Fan 2 is on the right.
  • Page 960 4. Replacement and Adjustment 2. Disconnect and unfasten the fan. 3. Remove the fan. There is no bracket.

  • Page 961: Ac Drive Board Fan

    Fans, Switches AC Drive Board Fan 1. Remove the rear covers. page 482 2. Open the controller box. page 490 3. The fan [1] is directly below the AC drive board [2]. 4. Disconnect the power cord. 5. Unfasten the corner plate [A] and ground wire. 6.
  • Page 962 4. Replacement and Adjustment 7. Disconnect the fan harness [A] in the corner of the machine. 8. Disconnect harness [B] above the fan. 9. Release the tabs at the left rear corner and front right corner of the fan. 10. Remove the fan. There is no bracket.

  • Page 963: Controller Fan

    Fans, Switches Controller Fan 1. Remove the rear upper cover. page 482 2. The controller fan is on top of the controller box. 3. Disconnect and unfasten the fan.
  • Page 964 4. Replacement and Adjustment 4. Remove the fan. There is no bracket. PFU Fan 1, 3, 4 1. Remove the right lower cover. page 481 2. Open the front door. 3. Remove the used toner bottle. 4. Push button A to open the vertical plate. 5.
  • Page 965 Fans, Switches 6. Disconnect the harness at the back of the vertical plate. 7. Lift the vertical plate [A] off its hinge pegs, and then remove it. 8. Lay the vertical plate [B] on a flat clean surface. 9. The upper fan [1] is the PFU fan 1, and the lower fan [2] is PFU fan 3.
  • Page 966 4. Replacement and Adjustment PFU Fan 1 1. Free the fan harness and disconnect it. 2. Remove the fan. PFU Fan 3 1. Free the fan harness and disconnect it.
  • Page 967 Fans, Switches 2. Remove the fan. PFU Fan 4 1. PFU Fan 4 is below the bottom paper feed unit.
  • Page 968 4. Replacement and Adjustment • The right lower cover, used toner bottle, vertical inner cover, and vertical plate must first be removed, the same as in the procedure to remove Fan 1 and Fan 3. 2. Disconnect the front of PFU 3 [A]. 3.

  • Page 969: Main Intake Fan

    Fans, Switches 7. Remove the fan. Main Intake Fan 1. Remove the rear upper cover. page 482 2. The main intake fan is at the rear right corner of the machine.
  • Page 970 4. Replacement and Adjustment 3. Disconnect fan duct [A]. 4. Slowly, pull the duct partially out of the machine so you can see connector [B], and then disconnect 5. Separate the fan and duct.

  • Page 971: Main Exhaust Fan

    Fans, Switches Main Exhaust Fan 1. Remove the rear upper cover. page 482 2. The main exhaust fan is at the rear left corner of the machine. 3. Disconnect fan bracket [A] on the left. 4. Disconnect the clamps and harness at [B] so they do not block removal of the fan bracket and duct. 5.
  • Page 972 4. Replacement and Adjustment 6. Remove the bracket and duct with fan attached. 7. Disconnect the duct [A]. 8. Separate the duct [B] from the fan. 9. Unfasten fan [C].

  • Page 973: Heat Exhaust Fan

    Fans, Switches 10. Separate fan and bracket. Heat Exhaust Fan 1. Remove the rear upper cover. page 482 2. The heat exhaust fan [1] is located below the main exhaust fan [2]. 3. Remove main exhaust fan. (See procedure above. The main exhaust fan must be removed before the heat exhaust fan can be removed.) 4.
  • Page 974 4. Replacement and Adjustment 5. Disconnect bracket at [A]. 6. Disconnect bracket at [B] (left screw). 7. Lift the duct and bracket [A] to unhook the front and rear. 8. Remove the bracket and duct [B] with fan attached.
  • Page 975 Fans, Switches 9. Lay the unit on a flat, clean surface. 10. Disconnect the duct. 11. Separate duct [A] from the fan. 12. Unfasten fan [B].

  • Page 976: Switches

    4. Replacement and Adjustment 13. Separate fan from bracket. Switches Power Switch 1. Open the front door. 2. Remove the power switch cover.

  • Page 977: Front Door Safety Switch

    Fans, Switches 3. Disconnect and remove the power switch board. Front Door Safety Switch 1. Open the front door. 2. Remove the power switch cover.
  • Page 978 4. Replacement and Adjustment 3. Unfasten the door switch. 4. Disconnect the door switch bayonet connector.

  • Page 979: Human Detection (Proximity) Sensor Switch

    Fans, Switches 5. Remove the switch. Human Detection (Proximity) Sensor Switch This sensor, mounted in the front, detects the presence of the operator as soon as he or she approaches within 1.8 meters of the front of the machine. • The sensor uses infrared so the maximum distance at which the operator's presence can be detected may vary with ambient temperature.
  • Page 980 4. Replacement and Adjustment • If the sensor fails to switch off, this will cause SC869-01. If the sensor fails to switch on, this will cause SC869-02. Test the Switch Do this procedure in order to identify the problem with the sensor. 1.
  • Page 981 Fans, Switches Switch Disassembly 1. Open the front door. 2. Remove the power switch cover. 3. Open the ADF. 4. Remove the front edge plate of the scanner unit.
  • Page 982 4. Replacement and Adjustment 5. Disconnect the operation panel on the left [A] and on the right [B]. 6. Slowly, turn the operation panel upside down, and then lay it on the scanner unit. 7. This detection device [1] and PCB [2] comprise the sensor.
  • Page 983 Fans, Switches 8. Remove the PCB (MSENS2). 9. Unfasten the detection device bracket, and then pull it out partially.
  • Page 984 4. Replacement and Adjustment 10. Open clamp [A] to free the harness, and then remove the bracket with harness attached [B]. 11. The MENS1 PCBs are in the bracket [1]. The PCB [2] is MENS2. 12. Disconnect the MENS1 PCBs [A], and then remove the top half of the bracket [B].
  • Page 985 Fans, Switches 13. Remove both MENS1 PCBs from the bracket. MENS1 PCB pair MENS2 PCB Harness Re-assembly 1. Set the MENS1 PCB pair in the bracket at the correct angle [A]. 2. The boss and screw holes will align correctly [B] only when the PCBs are set at the correct angle.

  • Page 986: Important Sp Codes: Fans, Switches

    4. Replacement and Adjustment 3. Clamp the harness between the two permanent binders on the harness. Important SP Codes: Fans, Switches Here is a list of SP codes related to testing and servicing the large number of fans and switches. Item SP No.

  • Page 987: Copy Image Adjustments: Printing/Scanning

    Copy Image Adjustments: Printing/Scanning Copy Image Adjustments: Printing/Scanning These adjustments must be performed after replacing any of the following parts: • Scanner wires • Lens block • Scanner motor • Polygon motor • Tandem tray side fences • Memory All Clear Image Adjustments: Printing Preparation 1.

  • Page 988: Blank Margin

    4. Replacement and Adjustment SP mode Specification Tray 1 (Tandem Tray) SP1002-001 Tray 2 (Universal Tray) SP1002-002 0 ±1.5 Tray 3 (Universal Tray) SP1002-003 Tray 4 SP1002-004 Japan Only SP1002-006 0±1.5 Duplex Tray SP1002-007 0±1.5 Blank Margin If the leading edge/side-to-side registration cannot be adjusted within specifications, adjust the leading/left side edge blank margin.
  • Page 989 Copy Image Adjustments: Printing/Scanning Letter What It Means Trailing edge blank margin Right edge blank margin Leading edge blank margin Left edge blank margin SP2101 Print Erase Margin SP mode Specification Leading Edge SP2101-001 2.5±2 mm Trailing Edge SP2101-002 Left edge SP2101-003 2±1.5 mm Right edge...

  • Page 990: Registration Buckle Adjustment

    4. Replacement and Adjustment Registration Buckle Adjustment When the customer is using special paper, buckle adjustment may be required if paper feed problems arise. • If the buckle is too large, this can cause wrinkling, creasing, or jams caused by sheets overtaking the sheets ahead of them in the paper path.

  • Page 991: Registration: Platen Mode

    Copy Image Adjustments: Printing/Scanning Registration: Platen Mode 1. Place the test chart on the exposure glass and make a copy from one of the feed stations. 2. Check the leading edge and side-to-side registration, and adjust them with the following SP modes if necessary.

  • Page 992: Adf Scanning Adjustments

    4. Replacement and Adjustment 2. Check magnification, and then SP2909-001 (Main Scan Magnification - Copy) to adjust magnification if required. Specification: ±2%. Sub Scan Magnification 1. Place the test chart on the exposure glass and make a copy from one of the feed stations. 2.

  • Page 993: Adf Skew Correction

    Copy Image Adjustments: Printing/Scanning SW 101 Operation Mode Free run (Entrance mode *1, simplex, no registration) Free run (Entrance mode, simplex, continuous scanning) Motor test (feed, transport, exit motors) *1: The entrance mode disregards paper size. Skew correction is performed at the scanning roller. ADF Skew Correction If the skew with A4 SEF paper is more than 0.5/200 mm in the main scan direction, you can adjust the position of the ADF hinge [A] or adjust the appropriate SP codes below.
  • Page 994 4. Replacement and Adjustment ADF Vertical Registration (Front) Adjusts the vertical registration for the front in ADF mode. [–30 to +24/1 mm] -30 = -5.1 mm +24 = +4.1 mm ADF Vertical Registration (Back) Adjusts the vertical registration for the back in ADF mode. [–30 to +30/1 mm] -30 = -5.1 mm +30 = +5.1 mm...
  • Page 995 Copy Image Adjustments: Printing/Scanning • Normally, the interval sensor detects the leading edge of small originals (B6, A5, HLT), or originals for duplex copying, and delays the start of the scanning roller for the prescribed number of pulses to buckle the paper and correct skew. This feature can be switched on for all paper sizes with SP6020 (ADF Contact Mode In/Out).

  • Page 996: Lcd, Touch Screen Check And Calibration

    4. Replacement and Adjustment LCD, Touch Screen Check and Calibration Smart Panel Maintenance Mode You should perform the following checks and calibrations: • After replacing the operation panel or operation panel touch screen. • After clearing the memory • If the touch screen detection function is not working correctly 1.
  • Page 997 LCD, Touch Screen Check and Calibration 4. On the Service Screen, touch "System Device Settings" at the bottom of the menu. The Self Check screen opens. 5. There are two checks and two calibrations you will need to execute: LCD Check Touch Panel Check Touch Panel Calibration Multi Touch Calibration...

  • Page 998: Checks And Calibrations

    4. Replacement and Adjustment Checks and Calibrations LCD Check The LCD Check allows you to visually check the color reproduction of the LCD. The colors are displayed on screens in sequence: White > Back > Red > Green > Blue (RGB). 1.

  • Page 999: Touch Panel Check

    LCD, Touch Screen Check and Calibration After the last color (blue) is displayed, the Self Check menu opens again. Touch Panel Check This simple check opens one screen. 1. Touch "Touch Panel Check" on the Self Check menu. The detected position and nearest reference point is displayed for each of nine reference points on LCD screen.

  • Page 1000: Touch Panel Calibration

    4. Replacement and Adjustment The detected position and nearest reference point is displayed for each of nine reference points on LCD screen. 2. Touch to return to the Self Check menu. Touch Panel Calibration Calibrate the touch panel by touching the center of each plus sign (+) as it appears on the LCD screen. 1.

  • Page 1001: Multi Touch Calibration

    LCD, Touch Screen Check and Calibration 3. As you touch each plus sign, the next appears and waits for you to touch it. After you touch the last sign (upper right), the message in the center of the screen prompts you to confirm the correct completion of the calibration, or to try again.

This manual is also suitable for:

Mp 6503spMp 9003sp

Table of Contents